INSTALLATION AND SERVICE MANUAL PROHEAT X45 · ThismanualisprovidedtoassistanauthorizedPROHEAT...

INSTALLATION AND SERVICE MANUALPROHEAT X45

Rev. H

CONTENTS

A. SAFETY ...................................................................................... A-1

B. INTRODUCTION ......................................................................... B-1

C. MODEL DESCRIPTIONS............................................................ C-1

1.0 TECHNICAL SPECIFICATIONS ................................................. 1-11.1 PHYSICAL – X45 ..................................................................... 1-21.2 ELECTRICAL – X45 .................................................................. 1-41.3 TORQUE SPECIFICATIONS ........................................................ 1-6

2.0 OPERATING YOUR PROHEAT HEATER..................................... 2-1

3.0 INSTALLATION .......................................................................... 3-1

3.1 LOCATING THE HEATER ........................................................... 3-23.1.1 Select Your Location ...................................................... 3-23.1.2 General considerations................................................... 3-23.1.3 Mounting the Proheat Heater in an Enclosure................... 3-3

3.2 MOUNTING THE HEATER .......................................................... 3-43.2.1 Option A – Heater With Enclosure .................................... 3-43.2.1 Option B – Heater Without Enclosure ............................... 3-5

3.3 EXHAUST PIPE CONNECTION.................................................... 3-6

3.4 PLUMBING THE SYSTEM.......................................................... 3-73.4.1 General Considerations .................................................. 3-73.4.2 Option A – Engine Heat or Supplemental Heat .................. 3-83.4.3 Option B – Engine and Sleeper Heat ................................ 3-9

3.5 WIRING & ELECTRICAL CONNECTIONS.................................... 3-103.5.1 General Considerations ................................................ 3-103.5.2 Power Connection to Batteries ...................................... 3-113.5.3 Timer Connections (Optional) ........................................ 3-123.5.4 On/Off Switch Connections........................................... 3-133.5.5 Sleeper Fan Model Heater Wiring Details ....................... 3-143.5.6 Option A – OEM Heater & Proheat Thermostat ................ 3-143.5.7 Option B – OEM Heater & Thermostat ............................ 3-153.5.8 Option C – Auxiliary Sleeper Heater................................ 3-163.5.9 Option D – Auxiliary Sleeper Heater Current Limited ........ 3-173.5.10 Auxiliary Input Model Heater Wiring Details................... 3-183.5.11 Option A – Preheat Mode Supplemental Mode Operation... 3-193.5.12 Option B – Preheat and Supplemental Mode ................... 3-203.5.13 Option C – Standard Mode & Supplemental Mode .........3-20

3.6 FUEL SYSTEM....................................................................... 3-223.6.1 General Considerations ................................................ 3-223.6.2 Option A – 1/4" or 1/2" NPT Port ................................. 3-233.6.3 Option B – Existing Blank Fuel Sender Cover Plate .......... 3-243.6.4 Option C – Hole Drilled into Fuel Tank ............................ 3-243.6.5 Installation .................................................................. 3-25

3.7 FIRST TIME STARTUP............................................................. 3-26

4.0 PRINCIPLES OF OPERATION ................................................... 4-1

4-1 GENERAL DESCRIPTION ........................................................... 4-1

4-2 MODES OF OPERATION ............................................................ 4-54.2.1 Standard Mode – All Models ........................................... 4-54.2.2 Preheat Mode – Aux Input Models Only ............................ 4-64.2.3 Supplemental Mode – Aux Input Models Only ................... 4-7

i

5.0 TROUBLESHOOTING & REPAIR ............................................... 5-1

5.0.1 Troubleshooting a Problem........................................ 5-15.0.2 Example Proheat Behavior Error – Code 01................. 5-2

5-1 OPERATION INDICATORS, FUNCTION & COMPONENTDIAGNOSTICS ................................................................... 5-3

5.1.1 Operation Indicators ................................................. 5-45.1.2 Function Diagnostics ................................................ 5-5

01 Start................................................................... 5-502 Flame Out ......................................................... 5-1503 Coolant Flow ..................................................... 5-1604 Overheat........................................................... 5-1705 Voltage ............................................................. 5-18

5.1.3 Component Diagnostics................................................ 5-1906 Flame Sensor.................................................... 5-1907 Temp Sensor .................................................... 5-2108 Fuel Pump......................................................... 5-2309 Compressor ...................................................... 5-2310 Ignition Coil....................................................... 5-2511 Coolant Pump ................................................... 5-2712 Blower .............................................................. 5-3013 Sleeper Fan ...................................................... 5-3214 Hour Meter (Auxiliary Output) .............................. 5-33

5-2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS........... 5-345.2.1 Fuel Nozzle .................................................................. 5-345.2.2 Fuel Regulator.............................................................. 5-345.2.3 Air Compressor ............................................................ 5-345.2.4 Fuel Pump ................................................................... 5-345.2.5 Ignition Electrode ......................................................... 5-345.2.6 Coolant Pump .............................................................. 5-345.2.7 Blower......................................................................... 5-345.2.8 Fuse ........................................................................... 5-35

5-3 OPERATIONAL PROBLEMS...................................................... 5-375.3.1 Smoking exhaust ......................................................... 5-375.3.2 Low heat output ........................................................... 5-375.3.3 Engine temperature gauge reads low ............................. 5-375.3.4 Backfiring .................................................................... 5-37

6.0 MAINTENANCE .......................................................................... 6-16-1 WEEKLY MAINTENANCE ........................................................... 6-16-2 ANNUAL MAINTENANCE ........................................................... 6-1

6.2.1 Clean Heater Enclosure and Air Intake ............................. 6-26.2.2 Check Exhaust System ................................................... 6-36.2.3 Check Heat Exchanger.................................................... 6-36.2.4 Clean Flame Sensor ....................................................... 6-46.2.5 Check Cooling System.................................................... 6-46.2.6 Check Batteries ............................................................. 6-46.2.7 Check Fuel System......................................................... 6-56.2.8 Check Fuel Filter ............................................................ 6-56.2.9 Clean Nozzle.................................................................. 6-66.2.10 Replace Compressor Air Filter ....................................... 6-66.2.11 Check Electrical System ............................................... 6-76.2.12 Check Air Pressure....................................................... 6-86.2.13 Check Modes of Operation – Switch, Timer or OEM Signals .. 6-8

7.0 APPENDICES ............................................................................ 7-1

Bulletins 951528, 967329, SB0003, PB0034, SB0062

8.0 WARRANTY ............................................................................... 8-1

ii PROHEAT INSTALLATION & SERVICE

SAFETY

Throughout this manual, you will see notes labeled DANGER, WARNING,CAUTION and NOTICE to alert you to special instructions or precautionsconcerning a particular procedure that would be hazardous if performedincorrectly or carelessly.

Observe them carefully!

These safety alerts alone cannot eliminate all hazards. Strict compliancewith these special instructions and common sense are major accidentprevention measures.

DANGERImmediate hazards that will resultin severe injury or death.

WARNINGHazards or unsafe practices thatcould result in severe personalinjury or death.

NOTICEInformation that is important toproper installation or maintenance,but is not hazard-related.

CAUTIONHazards or unsafe practices thatcould result in minor injury orproduct or property damage.

A.

A-1SECTION A. SAFETY

ExhaustInhalation of exhaust gas (containing carbon monoxide) may cause severe personalinjury and/or death. Anyone suspected of suffering from CO inhalation should beremoved from the hazardous area and given medical assistance immediately.

Explosion HazardDo not operate heater where combustible fumes or airborne particles, such as saw-dust, are present.

FuelExercise extreme caution when working near fuel or fuel-filled equipment. Do notoperate heater during fueling operations. In addition, do not smoke or handle openflame equipment, such as a blowtorch, around fuel.

Fire HazardDo not place any flammable items around the heater and exhaust pipe.

BatteriesWear hand and eye protection when working near batteries. Do not smoke or use openflames near batteries.

ElectricalElectric shock can cause severe personal injury, burns, and death. Before working onany unit, disconnect the batteries. Use only approved materials and methods whenworking on the electrical system and follow local electrical codes. Never work withelectricity in wet conditions or when you are feeling fatigued.

Poisons/ToxinsFuel and coolant are toxic and in some cases, carcinogenic. Wear eye and handprotection at all times. Remove contaminated clothing immediately and washcontaminated skin. Do not breathe in vapors.

Moving/Hot PartsMoving/hot parts can cause severe injury and or death. Before working on any unit,shut it off. Do not operate any unit until protective covers have been replaced. Alwaysensure bolts and clamps are correctly torqued and secured. Inspect mechanical com-ponents periodically for damage and corrosion.

CoolantNever remove the filler cap when the engine is hot – escaping steam or scalding watercould cause serious personal injury. The coolant level in the expansion tank should bechecked at least weekly (more frequently in high mileage or arduous conditions). Alwayscheck the level when the system is cold. Unscrew the filler cap slowly, allowing thepressure to escape before removing completely. Never run the engine without coolant.

Prevent anti-freeze coming in contact with the skin or eyes. If this occurs, rinseimmediately with plenty of water. Anti-freeze will damage painted surfaces.

Never top-up with salt water. Even when travelling in territories where the water supplycontains salt, always ensure you carry a supply of fresh (rain or distilled) water.

California Proposition 65 WarningDo not operate heater in garages or in other closed or unventilated areas.Diesel exhaust and some of its constituents are known to the State of California tocause cancer, birth defects, and other reproductive harm.Electrical components in this product may contain lead, a chemical known to theState of California to cause cancer and birth defects and other reproductive harm.

SAFETY CONSIDERATIONS

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

DANGER

A-2 PROHEAT INSTALLATION & SERVICE

This manual is provided to assist an authorized PROHEATdealer to install and service a PROHEAT heater. Althoughtrucks have been used in the examples, applications forPROHEAT are by no means limited to trucks. PROHEATheaters are designed to be used on any diesel equippedvehicle including: trucks, buses (school, transit and coach),construction equipment, off road equipment, militaryequipment and cargo.

PROHEAT heaters are used in the following applications:

(1) Engine Block Heat – PROHEAT will preheat an engineblock to ensure reliable starting in cold weather. Atthe same time it may be used throughout the year toreduce the wear associated with cold starts.

(2) Cab or Sleeper Heat (engine off) – PROHEAT will supplyheat to the cab or sleeper. Drivers can sleep in comfortnot only in the cold of winter but also in the springand fall when the weather is miserable. Substantialsavings through reduced fuel consumption and enginewear can be obtained by not idling the engine.

PROHEAT Model X45

(3) Supplemental Heat (engine running) – as the efficiencyof modern diesel engines are improved there is nolonger adequate reject heat available to heat thevehicle’s interior. This is particularly true for buses.PROHEAT can be used while the vehicle is operatingto provide supplemental heat for the interior.

(4) Cargo Heat – PROHEAT can be used to provide heat toprotect valuable cargo such as produce or beveragesfrom damage due to freezing.

(5) Marine – Marine applications typically involve theengineering and installation of a complete hot-waterheating system of which PROHEAT is only onecomponent. Proheat recommends that only anexpert in marine hot-water heating systems install aPROHEAT on a boat. It is the installer’s responsibilityto ensure that the installation complies with allapplicable regulations.

INTRODUCTIONB.

B-1SECTION B. INTRODUCTION

B-2 PROHEAT INSTALLATION & SERVICE

MODEL DESCRIPTIONSC.

C-1SECTION C. MODEL DESCRIPTIONS

This manual covers all models of PROHEAT X45. Please refer to the X45 PartsBook at www.proheat.com for detailed part descriptions and part numbers.Included in the parts book are optional features such as a timer, sleeper fancontrol kit, impact switch (for school bus applications) and associatedinstallation and maintenance tools.

The following information describes the three general characteristics of X45models covered in this manual: voltage, enclosure and Proheat Control Module(PCM) options.

VOLTAGE CONFIGURATION: 12 V OR 24 V

The X45 is available in either a 12 V or 24 V models.

ENCLOSURE

An optional enclosure provides environmental protection.

PROHEAT CONTROL MODULE (PCM): SLEEPER FANOUTPUT OR AUXILIARY INPUT

The PCM comes in either a sleeper fan output or auxiliary input model. Thesleeper fan model is limited to a 3 amp output and is generally installed ontrucks that require sleeper fan power (it is only available on 12 V models).The Auxiliary Input model uses two special input pins that allow for a PreheatMode and Supplemental Mode. This operation is typically used for transit andcoach installation. Refer to page 4-2 for more information.

Sleeper Fan Output or Auxiliary InputIdentification.

Voltage Identification.

C-2 PROHEAT INSTALLATION & SERVICE

SECTION 1. TECHNICAL SPECIFICATIONS

TECHNICALSPECIFICATIONS

1.0

1-1

SYSTEM INPUTS

SWITCH 10 – 15 VDC (12V X45) | 20 – 30 VDC (24V X45)Standard Run ModePreheat Run Mode (Certain Models Only)Supplemental (Certain Models Only)

POWER 12 VDC or 24 VDC

X45 12V X45 24V

RATING 45,000 BTU (13 kW)

SYSTEM VOLTAGE 10 –15 VDC 20 – 30 VDCNominal Voltage Range

CURRENT DRAW 7.5 Amps 3.75 Amps

FUEL CONSUMPTION(Average to Maximum) 0.1 – 0.45 gal/hr. (0.4 – 1.7 L/hr.)

COOLANT FLOW 8.0 gal/min. (30 L/min.)

COOLANT TEMPERATURE (at Heater) 150°F to 185°F (65°C to 85°C)

OPERATING TEMPERATURE RANGE -40°F to +122°F (-40°C to +50°C)

IGNITION TYPE Electronic Spark Ignition

HEAT EXCHANGER CAPACITY 1 quart (0.95 L)

WEIGHT Heater ONLY 40 lbs (18 Kg)

WEIGHT Heater with Enclosure 55 lbs (25 Kg)

DIMENSIONS – HEATER (L x W x H) 18.9 x 11.2 x 10.6 inches(520 x 320 x 280 mm)

DIMENSIONS – ENCLOSURE (L x W x H) 20.2 x 12.3 x 10.5 inches(513 x 313 x 267 mm)

WARRANTY Two years parts and labor

SYSTEM OUTPUTS

HOUR METER Same as System Voltage(AUXILIARY OUTPUT) Maximum 1 Amp draw (over-load shut-off protection)

High-side switched

SWITCH/TIMER Same as System VoltagePOWER Maximum 1 Amp draw (over-load shut-off protection)

High-side switched

SLEEPER FAN Same as System Voltage(Certain Models Only) Maximum 3 Amp draw (over-load shut-off protection)

High-side switched

INDICATOR LIGHT Same as System VoltageMaximum 1 Amp draw (over-load shut-off protection)High-side switched

FUEL TYPES

COMPATIBLE Diesel (ULSD, #1, #2, Arctic), JP8, Jet A1Bio Fuels – Contact Proheat www.proheat.com

DANGERDO NOT use gasoline.

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1-2 PROHEAT INSTALLATION & SERVICE

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1-3SECTION 1. TECHNICAL SPECIFICATIONS

X45 WITH ENCLOSURE1.1.2

ELECTRICAL – X45

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Figure 1-4 PCM Electrical Connections – X45

1-5SECTION 1. TECHNICAL SPECIFICATIONS

PROHEAT INSTALLATION & SERVICE1-6

TORQUE SPECIFICATIONS1.3

FAN END CASTING• Apply anti-seize to bolts (3)

• Torque bolts (3) to 75±5 in/lbs (8.5±0.5 Nm)

REGULATOR• Apply anti-seize to cap screw

• Torque cap screw to 94±6 in/lbs (10.6±0.7 Nm)

FLAME SENSOR• Torque sensor to 25±3 in/lbs (2.8±0.3 Nm)

IGNITER• Apply anti-seize to igniter threads

• Ensure gasket is present before installing

• Torque igniter to 50±5 in/lbs (5.6±0.6 Nm)

COMBUSTION TUBE• Apply anti-seize to cap screws

• Torque cap screws (4) to 25±3 in/lbs (2.8±0.3 Nm)

SECTION 1. TECHNICAL SPECIFICATIONS 1-7

OVERHEAT SENSOR• Lubricate o-ring with o-ring lubricant

• Torque senor to 500±50 in/lbs (56±5.6 Nm)

TEMPERATURE SENSOR• Lubricate o-ring with o-ring lubricant

• Torque senor to 25±3 in/lbs (2.8±0.3 Nm)

AIR FILTER• Torque cap screw to 50±5 in/lbs (5.6±0.6 Nm)

BLOWER ASSEMBLY• Apply anti-seize to bolts (4)


PROHEAT CONTROL MODULE (PCM)• Apply anti-seize to bolts (3)



MAIN INTERNAL HARNESS• Torque bolt (1) to 10±2 in/lbs (1.1 +/- 0.2)

NOZZLE TO FAN END• Lubricate o-ring on nozzle with diesel

• Torque nozzle to 150±10 in/lbs (17±1.1 Nm)

BAND CLAMPS• Torque clamps (4) to 25±3 in/lbs (2.8±0.3 Nm)

NOZZLE REASSEMBLY• Torque nozzle (1) to 30±3 in/lbs (3.4±0.3 Nm)

ENCLOSURE LID (Optional)• Anti-seize recommended on bolts

• Torque clamps (2) to 30±3 in/lbs (3.4±3.4 Nm)

SECTION 1. TECHNICAL SPECIFICATIONS 1-9

HARNESS GROUND LUG• Apply anti-seize to bolt

• Torque bolt (1) to 75±5 in/lbs (8.5±0.5 Nm)

A

B

C

FUEL PUMP ASSEMBLYA

• Apply Loctite 242 to threads

• Torque bolts (2) to 25±3 in/lbs (2.8±0.3 Nm).

B• Lubricate o-ring with diesel fuel

• Torque relief valve to 22±2 in/lbs (2.5±0.2 Nm).

C• Apply Loctite 59241 sealant to threads

• Torque elbow (1) to 55±5 in/lbs (6.2±0.5 Nm) minimum or until

elbow is at correct orientation

FUEL FILTER• Lubricate o-ring with diesel fuel

• Torque nut (1) to 150±10 in/lbs (17±1.1 Nm)

OPERATING YOURPROHEAT HEATER

ENGINE HEAT ONLY1. Switch the ON/OFF switch located in the vehicle dash to “ON.”

The switch will light and the heater will cycle on. It will continue to operate untilthe coolant reaches 185˚F (85˚C) at the heater outlet and then cycle “OFF.”

When the coolant temperature falls below 150˚F (65˚C) at the heateroutlet, it will refire and repeat the cycle.It will continue to cycle until:a) the heater is switched “OFF,”b) the heater runs out of fuel,c) the vehicle battery voltage drops below 10.0 Volts, ord) an error occurs and the switch light flashes

(See Troubleshooting & Repair, Section 5)

NOTE: The PROHEAT may be operated if the engine is running or not running.

2. When engine preheat is no longer required, switch the PROHEAT heater“OFF.”

ENGINE AND SLEEPER HEAT1. Switch the ON/OFF switch located in the vehicle dash to “ON.”

The switch will light and the heater will cycle on. It will continue to operate untilthe coolant reaches 185˚F (85˚C) at the heater outlet and then cycle “OFF.”

When the coolant temperature falls below 150˚F (65˚C) at the heateroutlet, it will refire and repeat the cycle.It will continue to cycle until:a) the heater is switched “OFF,”b) the heater runs out of fuel,c) the vehicle battery voltage drops below 10.0 Volts, ord) an error occurs and the switch light flashes

(See Troubleshooting & Repair, Section 5)

NOTE: The PROHEAT may be operated if the engine is running or not running.

2. For sleeper heat – set the thermostat in the sleeper to the desiredtemperature. If the set temperature is higher than the temperature in thesleeper the fan will cycle “ON.” When the air reaches the set temperaturethe fan will cycle “OFF.” The fan will cycle “ON” and “OFF” to maintain theset temperature.

3. When engine and/or sleeper preheat is no longer required, switch thePROHEAT heater “OFF.”

2.0

NOTICERegular use of your PROHEATthroughout the year will improveits reliability. Weekly operation isrecommended.

NOTICEThe PROHEAT heater can beoperated by either using a toggleswitch or a 7 day timer.Refer to page 3-10 for WIRING &ELECTRICAL CONNECTIONS.

NOTICEThese instructions cover StandardMode operation that are normallyinstalled on trucks. To operate yourheater in Preheat or Supplemental,refer to page 3-18 to page 3-20 andpage 4-6 to page 4-7.

2-1SECTION 2. OPERATING YOUR PROHEAT HEATER

SECTION 3. INSTALLATION 3-1

INSTALLATION

The installation details described in this manual focuses on truck applicationsand does not cover all of the possible installations. As seen in the figuresbelow, the PROHEAT X45 is installed on a variety of equipment includingtrucks, school buses, coaches, drill rigs, mine dump trucks and excavators.In these cases the manual should be used as a guideline only.

There are seven major steps that must be completed to successfully installthe PROHEAT heater.

3.1 LOCATING THE HEATER......................................................... page 3-2

3.2 MOUNTING THE HEATER ....................................................... page 3-4

3.3 EXHAUST PIPE CONNECTION ................................................. page 3-6

3.4 PLUMBING THE SYSTEM....................................................... page 3-7

3.5 WIRING & ELECTRICAL CONNECTIONS ................................. page 3-10

3.6 FUEL SYSTEM .................................................................... page 3-22

3.7 FIRST TIME STARTUP.......................................................... page 3-26

Prior to the installation of your PROHEAT, consult your engine owner’s manualor engine manufacturer for any restrictions or changes that may apply toplumbing into the engine coolant system.

3.0

NOTICEIf additional installation information isrequired please contact your PROHEATDealer regarding your specificapplication.

For more technical information,please contact PROHEAT ProductSupport at www.proheat.com

®

®

Figure 3-1 Other Applications.

Figure 3-4 Allow minimum 6" clearancefor hose connections.


SELECT YOUR LOCATION

The most suitable location for mounting the heater will vary dependingon the type of vehicle. Recommended mounting locations are:

• Behind the cab across the frame rails (1).

• On either side of the frame rails (2).

• In an existing enclosure on the vehicle (step or toolbox) (3).

LOCATING THE HEATER

GENERAL CONSIDERATIONS

• Never mount the heater to two separate parts of the vehicle.

• Avoid mounting the heater in areas of excessive vibration.

• Do not mount the heater directly to the engine.

• Do not mount the heater beneath a wood floor without a proper fire wallabove the heater.

• Avoid mounting the heater in areas of excessive dust, dirt and moistureaccumulation.

• The heater must be easily accessed for service.

Figure 3-2 Recommended Mounting Positions

You Choose

Figure 3-3

1

2

2

3

COOLANT OUT

COOLANT INMINIMUMCLEARANCE 6"

FUEL IN

WARNINGNever locate the heater insidethe vehicle cab. (See Figure 3-3)

CAUTIONDo not weld PROHEAT heatermounting brackets to thevehicle frame.

If repairs to the vehicle requirewelding, disconnect the PROHEATpower cable at the PCM. This willprevent damage to the PROHEATelectronics.

3.1

3.1.2

3.1.1

Figure 3-5 Height Requirement


Heater must be mounted below the highest point in the cooling system. Anexpansion tank may be added to the coolant system above the heater if thisis not possible.

MOUNTING THE PROHEAT HEATER IN AN ENCLOSURE

Do not locate the heater in anairtight enclosure. If the heater is tobe mounted in an enclosure otherthan the PROHEAT enclosure,adequate air flow must be providedto ensure proper combustion. Theenclosure must also be adequatelyventilated so that the ambienttemperature inside the enclosuredoes not exceed 185 °F (85 °C).The openings must be positioned to prevent moisture dirt and snow fromaccumulating in the enclosure. The heater enclosure must be easilyaccessed for servicing of the heater.

Figure 3-7 Mounting Angle

Heater must be mounted within 5˚ of horizontal, as shown.

HIGHEST POINT INCOOLING SYSTEM

HEATER MUSTBE MOUNTEDBELOWHIGHEST POINT

PROHEAT ENGINE OR RADIATOR

5˚

5˚

5˚5˚

3.1.3

Figure 3-6 Adequate Air Flow

Figure 3-9 X45 Enclosure Base Dimensions


MOUNTING THE HEATER

Select Your Mounting Option

OPTION A – Heater With Enclosure

1. Remove the enclosure cover.

2. Drill the (4) mounting holes and exhaust pipe clearance hole.

3. Using the bolts supplied, fasten the enclosure to the mountingtray or brackets.

4. Ensure that the combustion tube can be removed for service.See Figure 1-2 on page 1-3 for service space requirements.

Figure 3-8 Mounting Tray

8 13/16"(223 mm)

5 3/4" (146 mm)

3/4" (20 mm) MOUNTING HOLES(4 REQUIRED)

16 11/16" (427 mm)

12"(306 mm)

20" (508 mm)

5" (127 mm)3" (76 mm) Dia.

5" (127 mm)

CENTERLINE OF ENCLOSURE

5" (127 mm)

1 5/8"(45 mm)

1 5/8" (45 mm)

3.2

3.2.1

3-5

Figure 3-10 X45 Mounting Plate Dimensions & Exhaust Hole

SECTION 3. INSTALLATION

OPTION B – Heater Without Enclosure

Heater supplied without an enclosure (mount in an existing enclosure on thevehicle ie. tool box). Heater supplied with an auxiliary mounting plate.

1. Ensure that the proposed enclosure is big enough for the heater.12 1⁄2W x 11H x 20 1⁄2L inches (318 x 280 x 521 mm)

2. Using the indicated dimensions, drill the (4) mounting holesand exhaust pipe clearance hole.

3. Ensure that the combustion tube can be removed for service.See Figure 1-2 on page 1-3 for service space requirements.

2.02"(51 mm)

3" (76 mm) Dia.

5.5"(140 mm)

1.0" (25 mm)

8.5" (216 mm)

5"(127 mm)

5" (127 mm)

7.5" (191 mm)

4 X .38" (10MM)MOUNTING HOLES

6.4"(163mm)

3.2.2

NOTICEUse anti-seize compound on fastenersto prevent galling and corrosion.

Figure 3-11 Exhaust Pipe


EXHAUST PIPE CONNECTION

1. Push the exhaust pipe through the hole in the enclosure and onto theexhaust outlet port of the heater. Ensure that the pipe is pushed ontothe spigot at least 11⁄2" (38 mm).

2. Route the exhaust pipe such that:• exhaust gasses do not enter the passenger compartment.• exhaust gasses do not enter the heater's combustion air inlet• exhaust system does not rest against or be directed toward any partsof the vehicle that may be damaged by heat (i.e. brake lines, seals, wires,rubber hoses or bumpers). The exhaust pipe may be have to be insulatedif it's within 6" of combustible materials or composite body parts

• the exhaust outlet does not face the same direction as vehicle travel• debris and snow will not plug the outlet• the exhaust pipe is protected from curb damage• the exhaust system should have a downwards slope for condensationto drain. If needed a 3/8" hole should be drilled into the exhaust pipeat the lowest point so that the condensation will drain.

3. Disassemble the exhaust pipe clamp and apply anti-seize compound tothe threads.

4. Assemble the exhaust clamp over the exhaust pipe (clamp goes insidethe enclosure) and tighten the nuts.

NOTE: 11⁄2" exhaust pipe should not exceed 5 ft and have no more than180 degrees of bends. The bends must be formed for best results.Do not use 90 degree welded pipe to turn corners.

WARNINGExhaust gases must not enterthe vehicle interior. Directexhaust pipe away from vehicle.

3.3

NOTICEIf additional information is required,please contact your PROHEAT Dealerregarding your specific application.Alternatively, please contact PROHEATProduct Support at www.proheat.com.

NOTICEUse of muffler or other restrictions in theexhaust system is not recommended.

EXHAUST CLAMPU BOLT (APPLYANTI-SEIZECOMPOUNDTO THREADS)

ENSURE THERE ARENO AIR LEAKS AROUNDTHE CONNECTION

DIRECTIONOF VEHICLETRAVEL

Use formed elbows.

Do not use welded90˚ elbows.

3-7SECTION 3. INSTALLATION

GENERAL CONSIDERATIONSCoolant flow must be maintained throughout the coolant systemunder all conditions.

• Keep the engine inlet and outlet ports as far apart as possible to maximizecross-flow through engine.

• Coolant pump and engine water pump must flow in the same direction.

• Ensure that no sharp kinks or bends exist in the hoses which may restrictcoolant flow.

• Avoid high points in the hose routing to prevent air traps.

• For systems requiring more than 50 feet of coolant line, contact ProheatProduct Support at www.proheat.com for coolant pump recommendations.

For plumbing the system use:

1⁄2" NPT pipe fittings or bigger.

3⁄4" ID heater hose.

NOTE: Use of silicone hose requires special hose clamps.

Shut-off valves are not required at the engine inlet and outlet connections butmay be used if desired. They should be left open at all times so that the heatercan be operated throughout the year.

Select Your Plumbing Option

Option A: Engine heat or supplemental heat.

The PROHEAT heats the engine block only.

NOTE: When the engine block is preheated you will have nearlyinstant heat from the dash heat exchanger.

Option B: Engine and sleeper heat.

The PROHEAT heats the engine block and the sleeper.

NOTE: Plumbing the PROHEAT through the dash fan is notrecommended.

PLUMBING THE SYSTEM

You Choose

Figure 3-12 Maximum cross-flow

MAXIMUMCROSS-FLOW

3.4

3.4.1

Figure 3-13 Engine Heat or Supplemental Heat

OPTION A – Engine Heat or Supplemental Heat

Instructions for Options A and B

1. Remove the radiator cap to release the system pressure.

2. Drain the coolant system.

3. Plumb the system as per Figure 3-13 or Figure 3-15

4. Add engine coolant to the system as per the specific enginemanufacturer’s recommendations and re-install the radiator cap.

NOTE: Plumbing the PROHEAT through the dash fan is not recommended.

NOTE: On coolant systems where the return from the PROHEAT is plumbed tothe bottom of the main coolant supply line from the radiator to enginepump, the return line must be moved to avoid loss of heat through theradiator.

DASH HEATER

ENGINE

RETURN TO ENGINE

SUPPLY TO PROHEAT

Figure 3-14 Correct Return Line Plumbing

®®

ENGINEENGINE

SUPPLY TO PROHEAT

RETURN TO ENGINE

SUPPLY TO PROHEAT

RETURN TO ENGINE

WARNINGOpening the radiator cap whenthe engine is hot may causeserious injury.


3.4.2

Figure 3-16 Engine and Sleeper Heat

Figure 3-15 Engine and Sleeper Heat


OPTION B – Engine and Sleeper Heat

For vehicles with solenoid valvesin the normally closed position.

Western Star

For best results these vehiclesshould use an auxiliary heater.

International with single heater

NOTE: Vehicles equipped with a combination heater/air-conditioner will havea solenoid operated shut-off valve in the heater unit. Typically this valveis normally open with the truck engine turned off and the key removed.(See Figure 3-16 for plumbing)

Due to the many options available in vehicle heating and airconditioning systems, the installer should be looking for anyrestrictions that may affect coolant flow, with vehicle ignition in the“OFF” position.

DASH HEATER

ENGINESUPPLY TO PROHEAT

RETURN TO ENGINE

OEM OR AUXILIARYSLEEPER HEATER

SOLENOID VALVEOEM COMBO HEATERSONLY (NORMALLY OPEN)

DASH HEATER

SUPPLY TO PROHEAT

RETURN TO ENGINE

SLEEPER HEATER

SOLENOID VALVE(NORMALLY CLOSED)

ENGINE

NOTICEThe PROHEAT PCM sleeper fan circuithas a one minute delay during ignition.Power to open a sleeper fan coolantvalve must be taken from anothersource such as the wire for the hourmeter (auxiliary output). (See PROHEATWiring Diagram on page 1-4.)

3-9

3.4.3

TO SLEEPER FAN OR AUX INPUTDEPENDING ON MODEL

TO BATTERIES

TO ON/OFF SWITCHAND/OR TIMER

WIRING & ELECTRICALCONNECTIONS

GENERAL CONSIDERATIONS

• Prior to installation of the PROHEAT Heater system, ensure that thevehicle batteries are in good condition.

• Do not kink or abrade wires when routing them through the vehicle duringinstallation.

• Ensure wires are well supported and secured with tie-wraps.

• Do not use acid core solder when making solder connections.

Major Electrical Connections Required

a) Power connection to batteries ................................................. page 3-11

b) Timer or ON/OFF switch connections........................................ page 3-12

c) Sleeper fan model heater connections (optional)....................... page 3-14

d) Auxiliary Input model heater connections (optional).................... page 3-18

Figure 3-18 Major Electrical Connections

Figure 3-17 Test Battery

WARNINGDo not use on positive groundvehicles.

CAUTIONIf repairs to the vehicle requirewelding, disconnect the PROHEATpower cable at the PCM. This willprevent damage to the PROHEATelectronics.

CAUTIONVehicles using ground side batterydisconnect switches must install anin-line 10 Amp fuse on the internalharness (Proheat part # PK0310).This will prevent damage to theharness and PCM, (refer to ServiceBulletin SB0003 in Appendix).


3.5

3.5.1

POWER CONNECTION TO BATTERIES

1. Route wire harness from PCM to the battery. Cut the harness to lengthas required.

2. Strip outer wire jacket of harness back to expose the positive (red) andnegative (black) leads. Strip the leads as shown and crimp the ringtongue terminals supplied to the wires. Connect the leads to the batteryterminals. (See Figure 3-19.)

3. Leave power harness disconnected. (See Figure 3-19.) Do not install untilPROHEAT coolant pump system has been purged of air. (See First TimeStartup, page 3-26)

NOTE: When power is connected to the PCM, all segments of the LED will flashon the PCM. This indicates that power has been supplied. See page 5-4for more information.

NOTE: Ensure the battery terminals are clean and free of corrosion. Removeand clean. Prior to re-connecting grease terminals with electricallyconductive grease.

Figure 3-19 Power Connection to Battery

POWER SUPPLYHARNESS

STRIP WIRE AS SHOWN ANDCRIMP TO TERMINAL

3/16"

RED (+) POSITIVE

BLACK (-) NEGATIVE

CAUTION12 Volt products should not usepower split from a 24 Volt system.This will cause uneven charging ofthe batteries.

NOTICESystems providing heat to both engineand sleeper require four (4) batteries.


3.5.2

Figure 3-20 Timer Connections

TIMER

1 ON

23

BLACK

RED

WHITE

GREEN

BLACK

TIMER

SWITCH INPUT HARNESS

RED

WHITE

GREEN

GREY

TO KEYSWITCH (OPTIONAL)

TIMER CONNECTIONS (OPTIONAL)

Black wire Ground

Red wire Power

White wire Operational signal from heater

Green wire “ON” Signal to heater

Grey wire Keyswitch backlighting (optional)

CAUTIONThe switch input circuit should onlybe used to supply power to theON/OFF Switch, the Timer, or as asignal to trip a relay. Failure tofollow this installation practice willresult in damage to the PCM.

NOTICEThe PCM must be reset (powerdisconnected and reconnected)when changing from a Timer to anON/OFF Switch or from an ON/OFFSwitch to a Timer.

Do not connect an ON/OFF Switchand a Timer in the same circuit.


3.5.3

Figure 3-22 ON/OFF Switch Connections

BLACK

RED

WHITE

GREEN

GROUND

ON SIGNAL

ON

OFF

POWER

INDICATOR

2" (51 mm)

3/16"(5 mm)

6. Connect the terminals to the switch as shown. (Figure 3-22)

NOTE: The PCM must be reset (power disconnected and reconnected) whenchanging from a Timer to an ON/OFF Switch or from an ON/OFF Switchto a Timer. Connecting an ON/OFF Switch and a Timer in the samecircuit will cause the indicator light to flash incorrectly.

ON/OFF SWITCH CONNECTIONS

1. Select a suitable location in the vehicle dash for the ON/OFF Switch.

NOTE: Many dash panels have switches which are not utilized. It may beconvenient to remove one and replace it with the PROHEAT switch.

2. Drill a 1⁄2" diameter hole through the dash for the switch. Make sure youhave clearance behind the dash for the switch wires and connections.Install the switch as per the diagram. (Figure 3-21)

3. Route the switch wire harness from the PCM to the dash panel. You willhave to pass the wire harness through the vehicle firewall. If possible usean existing hole. Use a grommet to prevent the wire from being damagedwhen it is passed through the hole.

4. Cut the harness to length.

5. Strip outer wire jacket of harness back to expose the 4 wires. Strip thewires as shown and crimp the supplied 1⁄4" spade terminals.

NOTE: Use fully insulated disconnects when connecting Switch.

Figure 3-21 ON/OFF Switch Assembly

DASH

NUT

ON/OFFSWITCH

SWITCHLABEL

1/2" DIA.HOLE

CAUTIONThe switch input circuit should onlybe used to supply power to theON/OFF Switch, the Timer, or as asignal to trip a relay. Failure tofollow this installation practice willresult in damage to the PCM.

NOTICEThe PCM must be reset (powerdisconnected and reconnected)when changing from a Timer to anON/OFF Switch or from an ON/OFFSwitch to a Timer.

Do not connect an ON/OFF Switchand a Timer in the same circuit.


3.5.4

SLEEPER FAN MODEL HEATER WIRING DETAILS

You Choose

These installation options allow the operator to:

1. Run the PROHEAT with the ignition key in the “OFF” position.

2. Return full control to the OEM system in normal operation mode.

Select one of the following wiring options

NOTE: PROHEAT IS NOT RESPONSIBLE FOR CHANGES IN SLEEPERFAN SYSTEMS BY ORIGINAL EQUIPMENT MANUFACTURINGCOMPANIES.

Due to the wide variety of wiring schematics that exist, we emphasize thatif you are in any doubt you should contact your dealer or PROHEAT ProductSupport at www.proheat.com

Option A: Used when climate control systems in sleepers require one ormore of the following features to be controlled.

1. Normal OEM fan speed selection.

2. A separate thermostat is required to turn the sleeper fanmotor “ON” and “OFF” because the OEM system uses aconstant running fan.

3. A valve in the sleeper heater coolant line regulates the flow andmust be fully opened when the PROHEAT is running.

4. Prevent possible back-feeding on ground side switchedsystems.

Option B: Used in larger sleepers requiring greater fan speed to providesufficient air movement to the sleeper. This allows the driver toselect the fan speed.

Option C: Used when a dedicated auxiliary heater is required.

Option D: Limits the power provided to the sleeper fan motor to3 Amps. With this system the total electrical draw is controlledby PROHEAT.

NOTE: For larger systems in the latest model trucks this may not provideenough fan speed and therefore Option A, B or C should be used.


3.5.5

OPTION A – OEM Heater & Proheat Thermostat

Please go to www.proheat.com for equipment specific installation instructions.

3.5.6

NOTICEThese instructions require a SleeperFan model. For more information seepage 4-2.

NOTICESleeper Fan output does not supplypower during ignition (1 minute afterswitch ON). DO NOT use for controllingcoolant valves. See page 4-5 foroperational sequence information.

The Hour Meter (Auxiliary) Output maybe used to control supplemental relaysto turn on coolant valves.

If additional installation information isrequired, please contact your PROHEATDealer or Product Support atwww.proheat.com

Figure 3-23 Option B

1. Make sure the vehicle ignition is switched “OFF.”

2. Locate the PROHEAT thermostat in a central area of the sleeper,approximately 12" above the bunk. Avoid direct air flow from sleeper fanducts. (Figure 3-25)

3. Remove the adjusting knob and face cover. Mark and drill mountingholes. Mount thermostat using the screws provided. (Figure 3-27)

4. Install relay 1, always between OEM sleeper fan control and OEMthermostat.

NOTE: The constant power supply wire must be of sufficient size to handlesleeper fan motor electrical current draw.

5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to length.Connect white wire to terminal 1 of the thermostat.

6. Route a wire from terminal 2 of the thermostat to relay 1 (can be cut from leftover wire harness). Ground the relay using PROHEAT sleeper fan groundwire (black).

PROHEATTHERMOSTAT

RELAY 1 STANDARD12 OR 24/30 AMP

WHITE

BLACK

15 AMP

SLEEPER FANHARNESS

PCM

OEM THERMOSTAT

OEMSLEEPERHEATER

ASSEMBLY

VEHICLEFUSE

PANEL

FAN MOTOR(SINGLE WINDING TYPE)

RESISTOR ASSEMBLYNOTE: MAY OR MAY NOT BE LOCATEDINSIDE SLEEPER HEATER ASSEMBLY

WHITE

CONSTANT POWERSOURCE(i.e. CIGARETTE LIGHTER)

OEM FANMOTOR

CONTROL(2 OR 3 SPEED)


OPTION B – OEM Heater & Thermostat3.5.7

Figure 3-24 Option C



2. Locate the auxiliary heater in a suitable area of the vehicle. Install plumbingand air duct connections as per the manufacturer’s recommendations.

3. Locate the PROHEAT thermostat in a central area of the sleeper,approximately 12" above the bunk. Avoid direct air flow from sleeper fanducts. (Figure 3-25)


5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut tolength. Connect white wire to terminal 1 of the thermostat using the forkterminal provided. Black wire is not used.

6. Route a wire from terminal 2 of the thermostat to an appropriate wire onthe sleeper fan motor. Make a splice connection and seal the splice withtape or heat shrink.

NOTE: The electrical power and operation in this option is controlled by thePROHEAT. See Option B should a relay be required to provide moreelectrical power.

PCM

SLEEPER FANHARNESS

AUXILIARYSLEEPER HEATER

THERMOSTAT

11

34

2 2

BLACK

WHITE

WHITE

SPLICE WIRES

ORANGEFAN MOTOR(MULTIPLE WINDING TYPE)

RED(NOT USED)

GROUND

10 AMPFUSE

WARNINGSystems using a ground sidebattery disconnect must installa 10 Amp fuse to protect thesleeper fan harness.

OPTION C – Auxiliary Sleeper Heater3.5.8

Thermostat Wire Connection DetailScrew # Wire Colour

1 White (from PCM)2 White (to sleeper heater)3 Not used4 Not used


Figure 3-28 Option D

Figure 3-26 Isolator Detail

Figure 3-27 Thermostat Detail

Figure 3-25 Thermostat Location


2. Mount the isolator in the sleeper fan motor area to a solid metal surfacewith the screw provided. Cut OEM wire to sleeper fan motor and connectisolator in series. Connect using 1⁄4" spade connectors provided. (Figure3-26) Wire end from resistor pack connected to isolator terminal marked“IGNITION.” Wire end from sleeper fan motor connected to isolatorterminal marked “FAN.”

3. Locate PROHEAT thermostat in central area of sleeper, approximately 12"above the bunk. Avoid direct air flow from sleeper fan ducts. (See Figure 3-25.)


5. Route sleeper fan harness from PCM to PROHEAT thermostat. Cut to length.Connect white wire to terminal 1 of the thermostat. Use fork terminal provided.Black wire not used.

6. Route a wire from terminal 2 of the thermostat to the isolator terminal marked“HEATER.” Connect using fork and spade terminal provided. (Can be cut fromleft over wire harness.)

NOTE: For large sleepers this MAY NOT provide enough fan speed andtherefore option A, B or C should be considered.

3/16"(5 mm)

MOUNTING SCREW

BASEFACE

ISOLATOR IGNITION

WHITE

WHITE

FAN

HEATER(PROHEAT)

BLACK WIRE(NOT USED)

112234

SLEEPER FANHARNESS

PROHEATTHERMOSTAT(SEE WIRECONNECTIONDETAIL)

PCM

OEM THERMOSTAT

OEM FANMOTOR CONTROL(2 OR 3 SPEED)

OEM SLEEPERHEATER ASSEMBLY

VEHICLEFUSE PANEL

FAN MOTOR(SINGLE WINDING TYPE)

M

RESISTOR ASSEMBLYNOTE: MAY OR MAY NOTBE LOCATED INSIDESLEEPER HEATERASSEMBLY

MUST BE BOLTED TO AMETAL SURFACE FORHEAT SINKING

Thermostat Wire Connection DetailScrew # Wire Colour

1 White (from PCM)2 White (to isolator)3 Not used4 Not used

OPTION D – Auxiliary Sleeper Heater Current Limited3.5.9

NOTICESleeper Fan output does not supplypower during ignition (1 minutes afterswitch ON). DO NOT use for controllingcoolant valves. DO NOT use forcontrolling coolant valves. See page4-5 for operational sequenceinformation.


These installation options allow the operator to:

1. Run the PROHEAT in Preheat Mode or Supplemental Mode alone.

2. Run the PROHEAT in the Preheat and Supplemental Mode.

3. Run the PROHEAT in Standard Mode (Proheat Timer option) and using theSupplemental Mode.

In addition to the Standard Operating Mode, there are two other operating modes:Preheat and Supplemental. One operating mode is for one button preheatingthe engine and the second is for supplemental heat while the vehicle is beingoperated. The benefits include easier operation for the driver; simplifiedinstallation; eliminates need for extra control relays; and increases reliabilityby reducing unnecessary heater operation.

The feature that makes this Auxiliary Input Model unique is that the PCM(Proheat Control Module) has three inputs to turn the heater on; one for eachoperating mode. The following is a description of the three operating modes.

Standard Heat ModeCoolant temperature is monitored via a built in sensor. When the temperature atthe Proheat is below 150° F (65° C)* the Proheat operates, heating the coolant to185° F (85° C) at which point it stops burning fuel and goes into Standby withonly the coolant pump running. Standard Heat Mode is typically activated byuse of a toggle switch which must be manually switched off. If the switch is notturned off the heater will continue to run overnight. Since the coolant pumpruns continuously in this mode, It is possible to accumulate a high number ofcoolant pump operating hours vs heater run hours. Use of supplemental modeis recommended in conjuction with standard mode in many cases.

Supplemental Heat ModeThe amount of heat required varies depending on engine load, outside temperature,frequency of door opening, etc. Recognizing this varying demand for heat, theProheat monitors the conditions and supplies heat only when required. Whenheat is not required, the Proheat puts itself into supplemental standby, shuttingoff the coolant pump, thereby avoiding additional run hours on the pump. Thisis ideal for transit and coach applications.

In order to simplify operation, this function is fully automatic and invisible tothe operator. The Proheat picks up a signal that the engine is running, and thenmonitors the coolant temperature via a built-in sensor. If the coolant temperatureat the Proheat is below 150° F (65° C)* the coolant pump is activated for threeminutes*. This causes coolant in the engine to be circulated through the Proheat.If after three minutes* the coolant temperature is above 150° F (65° C)*, theProheat will turn off the coolant pump and return to supplemental standby. Ifthe coolant temperature remains below 150° F (65°C)*, the Proheat will operateand continue to supply heat to the system until the coolant temperature reaches185° F (85° C). The Proheat then shuts itself off, returns to supplementalstandby, deactivates the coolant pump and waits for the coolant temperatureto fall below 150° F (65° C)*, and the cycle is repeated.

The Proheat switches off when the engine stops, thus avoiding the problemof the driver forgetting to switch the unit off and leaving it running overnight.

AUXILIARY INPUT MODEL HEATER WIRING DETAILS3.5.10

NOTICEThese instructions require a AuxiliaryInput model. For more information seepage 4-2.

NOTICEThe Preheat and Supplemental modesare generally used by transit andcoach applications.

NOTICEThe PROHEAT must have coolantflowing through it when it ismonitoring temperature.

NOTICESupplemental operation will not overridethe Standard Mode operation (ProheatTimer runs in Standard Mode).


Note also that the Supplemental Heat Mode has priority over the PreheatMode and will cause the Preheat Mode to drop out.

NOTE: There is a thirty second delay in response to both an “ON” and “OFF”signal*. This is to allow time for the vehicle to start before the heateris activated in Supplemental Heat Mode.

* There are special OEM versions for Supplemental Mode. For example, temperature thresholds may have a lowthreshold of 160ºF (71ºC) rather than 150ºF (65ºC) and a reduced coolant pump Pre-run time of 30 secondsrather than three minutes. Please contact Proheat Technical Support for more information.

Preheat ModeFor those fleets with outdoor parking, preheating is often essential in order tostart the engine in cold weather. Since much of an engine’s wear occurs duringstart-up, preheating. Preheating reduces this wear and contributes to longerengine life and reduced operating costs.

The Preheat Mode is activated by use of a momentary contact switch. This willtypically be activated each morning by the maintenance personnel an hour orso prior to pull out. The Proheat then runs in a mode similar to Standard HeatMode, heating the coolant which is circulated through the engine block. Theadvantage of this system is the manner in which it is switched off. No operatorinput is required. The Proheat has a built in time-out feature to prevent the heaterfrom running indefinitely. If the bus is not needed for pull-out, the Proheat willswitch itself off after 90 minutes of operation. Starting the engine will alsocause the preheat mode to end (if Supplemental mode is wired). To manuallyend preheat mode simply depress the momentary contact switch.

Please refer to the wiring diagrams on page 1-4 and page 3-21.

Select one of the following wiring optionsNOTE: PROHEAT IS NOT RESPONSIBLE FOR CHANGES IN ELECTRICAL

SYSTEMS BY ORIGINAL EQUIPMENT MANUFACTURING COMPANIES.

Option A: Run the PROHEAT in Preheat Mode or Supplemental Mode alone.

Option B: Run the PROHEAT in the Preheat and Supplemental Mode.

Option C: Run the PROHEAT in Standard Mode (Proheat Timer optional)and using the Supplemental Mode.

OPTION A – Preheat Mode or Supplemental Mode Operation

The instructions below are general in nature. It is up to the installer to selectappropriate switches and use proper electrical connection methods. If moreinformation is required, contact your Authorized Proheat Dealer or ProheatProduct Support at www.proheat.com

1. Select the operation mode of choice. Note that Preheat may be wired asPreheat Option 1 or Preheat Option 2 as shown in Figure 3-29. Inaddition, note to that the engine run signal may be off the alternator,multiplex or others.

2. Wire the Preheat Mode or Supplemental Mode as shown in Figure 3-29.Install hardware as required on the vehicle.

3. Install an Indicator Light near the vehicle operator.

You Choose

3.5.11

WARNINGWhen wiring for SupplementalMode, ensure to install Mechanic’sDisable Switch in order todisable Supplement Mode forsafety requirements.


OPTION B – Preheat and Supplemental Mode


1. Identify engine run signal. This may be off the alternator, multiplex or others.

2. Install hardware as required on the vehicle as shown in Figure 3-29.

3. Choose either Preheat Option 1 or Preheat Option 2. Install hardware asrequired on the vehicle as shown in Figure 3-29.

4. Install an Indicator Light near the vehicle operator.

3.5.12

3.5.13

WARNINGWhen wiring for SupplementalMode, ensure to install Mechanic’sDisable Switch in order todisable Supplement Mode forsafety requirements.

WARNINGDO NOT connect an ON/OFF Switchand a Timer in the same circuit.

NOTICESupplemental operation will notoverride the Standard Mode operation(Proheat Timer runs in Standard Mode).

OPTION C – Standard Mode (Proheat Timer Optional)and Supplemental Mode


1. Install the timer as per Section 3.5.3 or the switch as per Section 3.5.4.See Figure 3-29.

2. Identify engine run signal. This may be off the alternator, multiplex or others.

3. Route and connect engine run signal to wire A on the auxiliary inputconnector. Install hardware as required on the vehicle.


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page

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Select Your Fuel Pick-up Installation Option

Option A: Fuel pick-up to be installed in an existing 1⁄4”or 1⁄2” NPT portin fuel tank.

Option B: Fuel pick-up to be installed in an existing blank fuel sendercover plate.

Option C: Fuel pick-up to be installed in a hole drilled into thefuel tank.

You Choose

FUEL SYSTEM

GENERAL CONSIDERATIONS• Use a dedicated 1/4" ID fuel line between the fuel tank and heater meetingSAE 30R9. (Fuel line length not to exceed 50' with a maximum rise of 10'.)

Ensure fuel lines are routed away from all heat sources, well secured and willnot abrade.

• Ensure clamps are secure at fuel pump and fuel pick-up.

• Ensure the proper fuel line clamps with uniform 360° compression are used.

• Use of a fuel filter is not recommended. All models have a built in fuel filterat the fuel inlet fitting on the heater.

Figure 3-30 Do not kink or pinch fuelline when routing lines.

Figure 3-31 Fuel Supply Height Requirement

50' MAXIMUM LENGTH OF FUEL LINE

10' MAXIMUM RISE

CAUTIONDO NOT use fuel lines and pick-uptubes less than 1/4" ID or greaterthan 3/8" ID. Failure to use thecorrect line size may result inheater malfunction.


3.6

3.6.1


Figure 3-32 1⁄4" NPT Port

Locate an existing pipe thread port in the vehicle fuel tank and select the 1⁄4"or 1⁄2" NPT portion of the fuel pick-up that fits into that port. Apply a pipesealant paste to the fuel pick-up pipe threads prior to installation.

Figure 3-33 1⁄2" NPT Port

FUEL PICK-UP

1/4" NPT

FUEL TANK

EXISTING PORTIN FUEL TANK

FUEL PICK-UP

1/2" NPT

FUEL TANK

EXISTING PORTIN FUEL TANK

CAUTIONDo not use teflon tape as this willcontaminate the heater and enginefuel system.

3-23

OPTION A – 1/4" or 1/2" NPT Port3.6.2

This option requires a permanent modification to the fuel tank.

Select the location for the fuel pick-up in the vehicle fuel tank. Ensure sufficientclearance above the tank to get the fuel pick-up into the tank. Drill a 1" diameterhole in the tank.


Figure 3-35 Drill Hole in Tank

Locate an existing, blank fuel sender port in the vehicle fuel tank. Remove thecover plate, drill a 1" diameter hole and install the fuel pick-up as shown.

Figure 3-34 Blank Fuel Sender Port

WASHER

GASKET

COVER PLATE SUPPLIEDWITH FUEL TANK(REQUIRES MODIFICATION)

GASKET

WASHER

FUEL SENDER PORT IN TANK

WASHER

GASKET

GASKET

WASHER

DRILL 1" DIA. HOLEIN FUEL TANK

NUT

NUT

WARNINGDrilling the fuel tank may not beacceptable in some jurisdictions.Do not drill the fuel tank onpassenger carrying vehicles suchas school buses.

CAUTIONTo prevent fuel systemcontamination do not allow drillchips to fall into the fuel tankwhen drilling the hole.

OPTION B – Existing Blank Fuel Sender Cover Plate3.6.3

OPTION C – Hole Drilled into Fuel Tank3.6.4


Figure 3-37 Fuel Pick-up Depth

INSTALLATION

Figure 3-36 For some situations wherethe fuel pick-up is too farfrom the bottom of the tank,an extension from left overfuel line can be added. 1. Determine the depth of the fuel tank at the desired fuel pick-up location.

Cut the fuel pick-up 3 to 4” shorter as shown in Figure 3-37.

2. Install the pick-up into the fuel tank as per selected option.

3. Route the fuel line from the heater to the fuel pick-up. Ensure the fuel lineis well secured and will not abrade.

4. Attach the fuel line to the heater fuel pump fitting and the fuel pick-upwith hose clamps. Lubricating the fittings with fuel may ease theinstallation effort.

Figure 3-38 Fuel Line Connection Detail

3"-4" CLEAR

HOSE CLAMP

GROMMET

FUEL LINEFUEL TANK

FUEL PICK-UP

FUEL HOSE CLAMP

FUEL LINE

3-4" CLEAR OF BOTTOM OF TANK

CUT BOTTOMOF FUEL PICK-UPAT AN ANGLE

45˚±15˚

3.6.5

FIRST TIME STARTUP

1. Inspect the entire installation for:

a) loose bolts,b) loose hoses and hose clamps,c) loose wires and wire connections,d) kinked or pinched hoses or wires,e) battery connection for correct polarity, andf) coolant supply and return location on the engine.

2. Fill the vehicle cooling system with coolant as per owner’s manual orengine manufacturer’s recommendations.

3. Place dash heater control in the full “HOT” position. Turn air conditioning“OFF.”

NOTE: If shut-off valves are installed make sure they are fully “OPEN.”

4. Start the vehicle engine and run it at a fast idle for 5 to 10 minutes to purgeair from the heater and coolant system. While the engine is running:

a) make sure the coolant is flowing freely,b) inspect hoses and fittings for leaks,c) check the coolant level in the radiator and add coolant as necessary.

5. Shut the engine “OFF.”

6. Connect the power harness. All segments of the LED will flash on thePCM. This indicates that power has been supplied. See page 5-4 formore information.

7. Start the PROHEAT heater using the ON/OFF switch. The indicator lampshould be lit with a solid red light. Go to the heater and observe its operation.Test Preheat and Supplemental Mode operation if equipped. Refer to page 3-18 and page 4-5 for proper information.

Sequence of Events:a) Coolant temperature must be less than 150˚ (65˚C).b) “ON” light on PCM should be lit.c) You should hear the coolant pump, blower and compressor start.

Looking through the inspection port you should see a spark anda flame.

d) The spark will stop after 60 seconds and the heater will continueto run.

NOTE: If the indicator lamp in the ON/OFF Switch flashes upon initialstartup – WAIT. The heater will attempt a restart in 3 minutes.In some cases it takes longer for the fuel pump to prime the emptyfuel lines during the initial start. This is usually the case if the fuellines are long (it may take a few restarts). If the light continues toflash after the restart, then there is a problem.The Troubleshooting & Repair section of this manual will assistyou in correcting the problem.


3.7


8. Once the heater is started it will continue to run until the coolanttemperature reaches 185˚F (85˚C) at heater outlet, then it will shut off.

NOTE: The vehicle dash temperature gauge may read significantly lessdepending on the location of the sender unit on the engine.

Sequence of Events for Shutdowna) Fuel pump and compressor shut off.b) The blower will run for 3 minutes on Cool Down (Purge) cycle then

shut “OFF.”c) The water pump will continue to run.

9. The heater will restart when the coolant temperature falls below 150˚F(65˚C) at heater outlet, as long as the ON/OFF switch is left “ON.”

10. If the vehicle has been equipped with the sleeper heat option then:a) Adjust the PROHEAT sleeper thermostat to highest heat position.b) The sleeper heat exchanger fan will start blowing warm air.

11. Switch the ON/OFF switch to “OFF.” The red light will go out and theheater will Cool Down (Purge) for three minutes.

12. Inspect the installation again for leaks.

13. Install the enclosure cover.

14. TO ENSURE FULL WARRANTY COVERAGE COMPLETETHE WARRANTY CARD AND MAIL TO PROHEAT.

3-27

Figure 4-1. Sleeper Fan model shown.

SECTION 4. PRINCIPLE OF OPERATION 4-1

PRINCIPLEOF OPERATION

A gear pump driven from the same motor as the compressor pulls fuel fromthe tank. The fuel is filtered at the fuel pump inlet.

Reduces fuel to atmospheric pressure. Siphoning action from the nozzledraws fuel from the regulator. Without this siphoning there is no fuel flow.

A diaphragm type compressor supplies air to the fuel nozzle.

An automotive type ignition coil supplies high voltage to the ignition electrode,sparking to the combustion tube.

Circulates the engine coolant. An impeller style pump is used because of itslow current draw and free flow during engine operation. IT IS NOT SELF-PRIMING. The pump must be flooded and the system must be purged of allair for it to operate. (DO NOT run dry.)

Utilizes a microprocessor to monitor operating conditions and control outputs

1. Fuel Pump

2. Fuel Regulator

3. Air Compressor

4. Ignition Coil

5. Coolant Pump

4.0

1

3

5

2

4

6

GENERAL DESCRIPTION4.1

17


to the motors and sensors. It has powerful diagnostics to assist introubleshooting. One of the key features is the diagnostic display on thefront of the PCM which has a display LED to indicate function orcomponent problems. The PCM comes in a "Sleeper Fan 12V" or "AuxInput 12V or 24V" model. The PCM model can be identified by looking atthe lexan decal as shown in Figure 4-2.

• The "Sleeper Fan" model has an output with a special current limitingfeature which, if used, limits the current draw of the sleeper heater fanto 3 Amps. This is done to control the total current draw on the vehiclesbatteries. This operation is typically used for truck installations.

• The "Aux Input" model uses two special input pins (see ElectricalDrawing on page 1-4) that allow for a Preheat Mode and SupplementalMode operation. This operation is typically used for transit and coachinstallation.

NOTE: See "Modes of Operation Section" for a description of the operatingmodes used for both the "Sleeper Fan" and "Aux Input" Models

NOTE: The PROHEAT PCM “Sleeper Fan” circuit has a one minute delayduring ignition.

NOTE: The PROHEAT PCM is unique in that it uses “ground-side” switchingfor the blower, compressor, coolant pump and ignition coil. Thepositive wire to the motors and ignition coil will show voltage evenwhen the heater is switched “OFF.”

6. PROHEAT ControlModule (PCM)

Figure 4-2 LED will light to indicate a problem. Switch or Timer indicator light willflash to indicate the diagnostic code (page 5-3).

PCM MODEL IDENTIFICATION.SLEEPER FAN MODEL SHOWN.

4-3SECTION 4. PRINCIPLE OF OPERATION

Figure 4-3

An air/fuel aspirating type spray nozzle (located inside housing). Thecompressed air flows through the nozzle at high speed creating a venturieffect. This siphons fuel from the regulator and combines it with the air,creating an extremely fine mist which is sprayed out of the nozzle into thecombustion chamber.

Uses an impeller-type fan to supply the combustion air at low pressure. Itis also used to cool and Cool Down (Purge) the combustion chamberduring the 3 minute shut-down sequence.

Allows visual inspection of the combustion process and is invaluable forreducing time spent on troubleshooting and servicing the heater.

A two-part cast aluminum housing. Coolant will typically rise 10˚ to 15˚F(6˚ to 8˚C) in temperature as it passes through the heat exchanger,depending on the flow rate.

9. Inspection Port

10. Heat Exchanger

8. Blower

7. Nozzle

11

10 13

7

9

14

2

12

8

The electrode is located near the nozzle just out of the air/fuel mixture path.During the ignition sequence the spark jumps the gap between the electrode andthe combustion tube, igniting the air/fuel mixture. Spark duration is 60 seconds.

Measures coolant temperature at the outlet port of the heat exchanger.

Protects the heater from damage should it be operated without coolant. Theoverheat breaker monitors the surface temperature of the heat exchanger casting.When the temperature reaches 286˚F (141˚C) the breaker “trips out.” This shutsoff the power to the air compressor—extinguishing the flame. The breaker canbe reset by pushing down on the red button (located under the rubber cap).

Photo-electrically measures the intensity of the flame. It is the flame sensorthat signals to the PCM that the air/fuel mixture is burning properly.

Is used to switch the heater “ON” and “OFF.” It has an indicator lamp thatdisplays a red light when switched “ON.” A flashing red light indicates a heaterdiagnostic code and one of the LEDs on the PCM diagnostic display will be lit.(See page 5-3 for details.)

Is used to switch the heater “ON” and “OFF.” This can be done manually or bya preset time and day. It has an indicator lamp that displays a red light whenswitched or timed “ON.” A flashing red light indicates a heater diagnostic codeand one of the LEDs on the PCM diagnostic display will be lit. (See page 5-3for details.)

On Sleeper Fan 12 V models (see page 4-2), the Proheat Control Module isequipped with a 3 A limited output. It is used to drive fans or other equipmentas determined by the installation (see page 3-1). The output is ON 60 secondsafter switch ON. In addition, it is also ON when there is a functional error (seepage 5-1 for details).

12. Coolant TemperatureSensor

11. Ignition Electrode

13. Overheat BreakerSensor

14. Flame Sensor

15. On/Off Switch

16. 7 Day Timer

17. Sleeper Fan(only output connector

shown)

T-II

CLOCK TIMER ID LIGHT(GREEN)

INDICATOR LIGHT(RED)

TIMER SETBUTTON

MANUALBUTTON

Figure 4-5 7 Day Timer

Figure 4-4 ON/OFF Switch

Indicator LightLocated in the Toggle


The ON/OFF switch (or Timer) lamp and the PCM “ON” LED will light. In addition,the Hour Meter (Auxiliary Output) will be powered. The PROHEAT goes to“Precheck”.

The PCM performs a short diagnostic cycle. This takes a few seconds to checkcomponents for proper ranges, checking for the presence of a flame, short-circuits and open circuits. If there are no errors indicated, the PROHEAT goesto “Ignition”.

The blower starts first, followed by the coolant pump, ignition spark, air compressorand fuel pump. The ignition electrode sparks for 60 seconds. Once the flamesensor detects a good flame, the PROHEAT goes to “Full Output". At 60 seconds,the sleeper fan output turns on (if equipped. See page 4-2 for more information).

The PROHEAT runs at Full Output until the coolant temperature reaches185°F (85°C) at the heater outlet. The PROHEAT shuts the flame off and goesto “Cool Down (Purge)”. Pu is displayed on the Proheat Control Module (PCM).

The air compressor and fuel pump shut off immediately. The blower and coolantpump continue to run. After 3 minutes, the blower stops and the PROHEATgoes to “Standby.”

MODES OF OPERATION

1. Switch “ON”Standard

Mode Signal

2. Precheck

3. Ignition

4. Full Output

5. Purge

STANDARD MODE – All Models

The PCM comes in a "Sleeper Fan" or "Aux Input" model. The PCM model canbe identified by looking at the decal as shown on page 4-2. Depending on themodel and installation (refer to electrical drawing), the X45 has only the StandardMode of Operation or combination of Standard, Preheat and SupplementalModes of operation. The following table defines the applicability:

Aux Input Operation Mode SummarySee page 3-18 for background information.

Operational Mode Sleeper Fan Model Aux Input Model

Standard Yes Yes

Preheat no Yes

Supplemental no Yes


4.2

4.2.1

Standard Heat Mode• normal operation of theProheat

• over-rides and drops outpreheat mode

• overrides supplementalmode

Supplemental Heat Mode• similar to standard modeexcept: coolant pumpdoes not run whenProheat is not firing

• overrides and drops outpreheat mode

• 30 second signal requiredbefore mode enabled

• 30 second signal removalbefore mode shut off

Preheat Mode• similar to standardmode Except: 90 minutetime out

• activated via momentarycontact push buttonswitch with latchinginternal to the PCM

Push the Preheat button and the PCM “ON” LED will light will turn on. In addition,the Hour Meter (Auxiliary Output) will be powered. The PROHEAT goes to“Pre-check.”

The PCM performs a short diagnostic cycle. This takes a few seconds to checkcomponents for proper ranges, checking for the presence of a flame, short-circuits and open circuits. If there are no errors indicated, the PROHEAT goesto “Ignition.”

The blower starts first, followed by the coolant pump, ignition spark, air compressorand fuel pump. The ignition electrode sparks for 60 seconds. Once the flamesensor detects a good flame, the PROHEAT goes to “Full Output".

The PROHEAT runs at Full Output until the coolant temperature reaches185˚F (85˚C) at the heater outlet. The PROHEAT shuts the flame off and goesto “Cool Down (Purge).”

The air compressor and fuel pump shut off immediately. The blower andcoolant pump continue to run. After 3 minutes, the blower stops and thePROHEAT goes to “Standby.”

The coolant pump circulates the coolant through the system until the temperaturedrops to 150˚F (65˚C) at the heater outlet. The Proheat returns to Precheckand repeats steps 2 to 6. The PROHEAT will continue to repeat this cycleuntil it is switched off, or will switch OFF automatically after 90 minutes.

If PROHEAT is in “Full Output”, it will Cool Down (Purge) first, then shuts off.If PROHEAT is in “Standby”, it shuts off immediately.When switched OFF, the Hour Meter (Auxiliary Output) will shut off.

NOTE: The PROHEAT will Cool Down (Purge) for 3 reasons:

• the coolant reaches 185˚F (85˚C)

• there is a function or component problem(See Troubleshooting & Repair on page 5-1)

• the PROHEAT is operating at Full Output when it is shut "OFF".

1. ActivatePreheat Signal

2. Precheck

3. Ignition

4. Full Output

5. Purge

6. Standby

7. After 90minutes or

Switched off

PREHEAT MODE – Aux Input Models Only


4.2.2

6. Standby

7. Switch “OFF”

The coolant pump circulates the coolant through the system until the temperaturedrops to 150˚F (65˚C) at the heater outlet; then it will enter Precheck andrepeat steps 2 to 6. The PROHEAT will continue to repeat steps 2 to 5 until itis switched “OFF.”

If PROHEAT is in Full Output, it will Cool Down (Purge) first, then shut “OFF”.If PROHEAT is in Standby, it will shut “OFF” immediately.When switched OFF, the sleeper fan output turns off (if equipped, see page 4-2).When switched OFF, the Hour Meter (Auxiliary Output) will shut off.

NOTE: The PROHEAT will Cool Down (Purge) for 3 reasons:•the coolant reaches 185˚F (85˚C)•there is a function or component problem(See Troubleshooting & Repair on page 5-1)•the PROHEAT is operating at Full Output when it is shut “OFF”

SUPPLEMENTAL MODE – Aux Input Models Only

The ‘ON” light and heater indicator will turn ON after 30 seconds of receivingthe signal. In addition, the Hour Meter (Auxiliary Output) will be powered.

The PROHEAT monitors coolant temperature until it drops below 150˚F(65°C). Once coolant temperature drops below 150˚F (65°C) the PROHEATgoes to “Pre-run”.

The coolant pump operates for 3 minutes to circulate coolant through thesystem. If the coolant temperature rises above 150˚F (65°C), the pump shutsoff and the PROHEAT returns to “Supplemental Standby”. If the coolanttemperature remains below 150˚F (65°C), the PROHEAT goes to Pre-check.

The PCM performs a short diagnostic cycle. This takes a few seconds to checkcomponents for proper ranges, checking for the presence of a flame, short-circuits, and open circuits. If there are no errors indicated, the PROHEAT goesto “Ignition”.

The blower starts first, followed by the coolant pump, ignition spark, air compressorand fuel pump. The ignition electrode sparks for 60 seconds. Once the flamesensor detects a good flame, the PROHEAT goes to “Full Output".

The PROHEAT runs at Full Output until the coolant temperature reaches 185˚F(85°C) at the heater outlet. The PROHEAT shuts the flame off and goes to“Cool Down (Purge)”. Pu is displayed on the Proheat Control Module (PCM).

The Air Compressor and Fuel Pump shut off immediately. The Blower and CoolantPump continue to run. After 3 minutes the Blower and Coolant Pump stop andthe PROHEAT goes to “Supplemental Standby” and repeats steps 2 to 7.

The “ON” light and the Heater Indicator turn off after 30 seconds of the signalbeing removed. If the PROHEAT is in the “Supplemental Standby” or “Pre-run”sequence the PROHEAT will turn off immediately. If the PROHEAT is in any otherfunction it will complete a “Cool Down (Purge)” function before turning off.When switched OFF, the Hour Meter (Auxiliary Output) will shut off.

NOTE: The PROHEAT will Cool Down (Purge) for 3 reasons:

• the coolant reaches 185˚F (85˚C)

• there is a function or component problem(See Troubleshooting & Repair on page 5-1)

• the PROHEAT is operating at Full Output when it is shut off.

1. ActivateSupplemental

Signal for30 Seconds

3. Pre-run

2. SupplementalStandby

4. Pre-check

5. Ignition

6. Full Output

7. Purge

8. RemoveSupplemental

Signal for30 Seconds


4.2.3

NOTICEThere are special OEM versions forSupplemental Mode. For example,temperature thresholds may have alow threshold of 160°F (71°C) ratherthan 150°F (65°C) and a reducedcoolant pump Pre-run time of 30seconds rather than three minutes.

SECTION 5. TROUBLESHOOTING & REPAIR

TROUBLESHOOTINGAND REPAIR

5.0

Problems with the PROHEAT and its operation will be indicated in two ways:

1. PROHEAT Diagnostic Faults indicated by means of a flashing diagnostic codeon an indicator light on the switch, Timer red manual light or OEM indicatorlight (installation options). See Example Proheat Behavior Error on page 5-2.

2. Operational problems may not be identified with a flashing diagnostic code(e.g. blown fuse, smoking exhaust, backfiring or low heat output. Go topage 5-34 to page 5-37.)

TROUBLESHOOTING A PROBLEM

Locate the PROHEAT, remove the enclosure lid if equipped and visually checkfor any problems with wiring harnesses, fuel leaks, coolant leaks, exhaustpipe damage and environmental conditions.

Inspect Proheat Control Module (PCM) display for error code. If PCM display isdifficult to view, determine the blink code on the switch, Timer red manuallight or OEM indicator light (installation options).

If no code is indicated, turn the PROHEAT off and then on again using theexisting operational switches, timer or a PROHEAT remote start switch(PROHEAT P/N 952925K).

Let the PROHEAT attempt to start and/or operate. Observe the operation.

NOTE: The PROHEAT will always attempt to start twice, as long as the coolanttemperature is below 150°F (65°C). If a fault is detected it will shut down, gothrough a Cool Down (Purge) and attempt a second start. After both attemptsto start or operate, the PCM will display a code and the switch, Timer redmanual light or OEM indicator (installation options) will blink the same code.

• After two consecutive start attempts, the PROHEAT will not attempt tostart again and goes into a hold state. In the hold state the switch, Timerred manual light or OEM indicator light (installation options) will blink theerror code(s) continuously. The PROHEAT will try again once the switch isturned "OFF" and then "ON" again.

• If the indicator light flashes, count the number of flashes and refer tothe troubleshooting diagnostic code description for that number on thefollowing pages.

• If the PROHEAT runs but is not performing or operating correctly, consultthe Operational Problems, Section 5.3 on page 5-37.

Troubleshooting and Repair Tools Required• Remote Start Switch (PROHEAT P/N 952925K)

Allows the service technician to work at the PROHEAT. Isolates the PROHEATfrom the existing vehicle system controls and comes with a built-in indicator light.

• Digital Air Compressor Test Gauge (PROHEAT P/N PK0037)Allows the service technician to check compressor pressure in order toensure for correct fuel delivery. (Note The analog Air pressure gaugePK0060 can also be used.)

STEP 1

STEP 2

STEP 3

STEP 4

5-1

5.0.1

NOTICETroubleshooting and repair is to beperformed by Authorized ProheatDealers.

Figure 5-1 Troubleshooting Tools.


The ON/OFF switch (or Timer) lamp and the PCM “ON” LED will light. In addition,the Hour Meter (Auxiliary Output) will be powered. The PROHEAT goes to“Precheck”.

EXAMPLE PROHEAT BEHAVIOR ERROR – CODE 015.0.2

1. Switch “ON”Standard

Mode Signal

The PCM performs a short diagnostic cycle. This takes several secondschecking components for proper ranges, checking for the presence of aflame, short-circuits and open circuits. If there are no errors indicated, thePROHEAT goes to “Ignition”.

2. Pre-check

The blower starts first, followed by the coolant pump, ignition spark, aircompressor and fuel pump. The ignition electrode sparks for 60 seconds.

3. Ignition

After two consecutive Code 01 errors, the PROHEAT goes into a hold state.No further start attempts will be made. Code 01 will be displayedcontinuously and the PCM LED “ON” light will turn “OFF.” In addition, theHour Meter (Auxiliary Output) will shut off.

The switch, timer red manual light or OEM indicator light will continue to flashonce, pause, flash and repeat.

NOTE: In order to restart the heater turn the switch “OFF” and back “ON”.

6. Hold State

The PROHEAT always restarts after one error detection (except for Codes 13and 14). After the 3 minute Cool Down (Purge), the PROHEAT will go throughPrecheck, Ignition and the Error Detection – Cool Down (Purge) cycle onemore time.

5. Steps 1 to 4are Repeated

If the flame sensor did not “see” a flame in 60 seconds after enteringignition, the air compressor and fuel pump shut off immediately. The blowerand coolant pump continue to run.

Code 01 will be displayed alternating with Pu. There will be one flash, pauseand then one flash repeating on the switch, timer red manual light or OEMindicator light. After 3 minutes, the blower stops and the PROHEAT attemptsto start again.

NOTE: Codes 13 and 14 will not cause the heater to shut down. The PROHEATreports the error and continues to run.

4. ErrorDetection –

Purge

The following is an example of an X45 PROHEAT behavior during an error.The following example shows the sequence of events when the PROHEAT isswitch “ON” in the Standard Mode (similar for Preheat and SupplementalModes). This sequence of events occurs for Codes 01 through 12. Codes 13and 14 do not put the heater into Cool Down (Purge) mode or shut down thePROHEAT; rather, the PROHEAT reports the error and continues to run.

SECTION 5. TROUBLESHOOTING & REPAIR 5-3

The microprocessor in the PCM continually monitors all the PROHEATsystems. If the internal diagnostics discover a problem, a diagnostic code willbe displayed on the PCM function display. The remote ON/OFF Switch, Timerred manual light or OEM indicator light (installation options) will also flash thediagnostic code followed by a pause and then repeat. The number of flashescorrespond to the numbered diagnostic code. For example, 5 flashesindicates a VOLTAGE ERROR. (See diagram below for a complete list ofoperation states and error flash codes.)

If multiple errors occur, multiple codes will be displayed. For example, if a 5and 9 error occurs together, the PCM LED will flash 5 and then 9. Similarly,the remote ON/OFF Switch, Timer red manual light or OEM indicator light(installation options) will flash 5 times, pause and then 9 times.

OPERATION INDICATORS,FUNCTION AND COMPONENTDIAGNOSTICS

Figure 5-3 Function Display Panel Detail & Error Flash Codes

CODE No. Description of Operating State No. ofand Diagnostic Codes Flashes

Operation Indicators

8.8. Power Up No Indicator

• Switch On (Standard, Preheat Solid Indicatoror Supplemental Mode)

Pu Cool Down (Purge) Solid Indicator

Function Diagnostics

01 Start 1

02 Flame Out 2

03 Coolant Flow 3

04 Overheat 4

05 Voltage 5

Component Diagnostics

06 Flame Sensor 6

07 Temp Sensor 7

08 Fuel Pump (See Note) 8

09 Compressor 9

10 Ignition Coil 10

11 Coolant Pump 11

12 Blower 12

13 Sleeper Fan 13

14 Hour Meter (Auxiliary Output) 14

NOTICEThe X45 fuel pump is a gear pumpdriven directly by the compressormotor. The fuel pump is NOT beingmonitored electrically. Should thiscomponent diagnostic code appearthere will be a fault in the main wireharness connector (See page 5-35,Figure 5-27) or in the PCM. Allmechanical problems with the fuelpump will be indicated as either aSTART (1) or a FLAME OUT (2)diagnostic code.

NOTICECode 13, Sleeper Fan, is onlyapplicable to "Sleeper Fan" models.Should this diagnostic code appearon "Aux Input" models there will bea fault with the PCM.

5.1

Figure 5-2 Remote On/Off Switch.

Operation States:8.8. – Power Up• – OnPu – Cool Down (Purge)

The operation indicators signal normal functioning of the PROHEAT. These twostates do not indicate a fault.

OPERATION INDICATORS

The ON indicator code communicates that the PROHEAT is operationally “ON”whenever the On LED is solid. This indicates a Mode of Operation (see page4-5) is active.

On

WARNINGThe "ON" LED indicates that the heater can start at any time. Refer topage 4-5 to page 4-7.

The PROHEAT will be in the Cool Down (Purge) state as defined in the Modesof Operation (see page 4-5) when “Pu” is displayed.

Purge

5.1.1

The Power Up indicator communicates that the PROHEAT power has beensupplied. All segments of the LED momentarily flash and then turn off.

Power Up


5-5SECTION 5. TROUBLESHOOTING & REPAIR

Function Errors:1 – Start 4 – Overheat2 – Flame Out 5 – Voltage3 – Coolant Flow

Errors displayed on the PCM diagnostic panel will cause the heater to shutdown. These diagnostic codes are usually the result of a system problem.

It is possible to have two or more diagnostic codes displayed at the sametime. A function diagnostic code may be displayed in conjunction with acomponent diagnostic code.

FUNCTION DIAGNOSTICS

A START diagnostic code. Indicates that the flame sensor did not see a flameduring the FULL 60 second ignition period.

If the START diagnostic code is displayed, switch the heater “OFF” and then“ON” to restart. Observe the exhaust and the heater operation through theinspection window.

Troubleshoot the Flame Out diagnostic code based on:

1 Fuel System.Go to page 5-6 to page 5-12, Steps 1 to 5.

• There is no fuel, fuel odor or atomized fuel coming from the exhaust pipe.

• There is no hot exhaust coming from the exhaust pipe.

• There is no flame visible through the inspection window.

2 Ignition System.

• There is raw fuel and/or atomized fuel and a raw fuel odor coming fromthe exhaust pipe. Go to page 5-13.

• There is no hot exhaust coming from the exhaust pipe.

• There is no flame visible through the inspection window.

3 Flame Sensor.Go to page 5-14.

• There is a flame and the combustion sounds good, the PROHEATappears to be operating normally.

• No smoke, raw fuel odor or atomized fuel is coming from the exhaust pipe.

Fuel System Schematic

The PROHEAT X45 fuel system operates on a venturi-style atomizing nozzletechnology. It operates similarly to a compressed air paint sprayer.

As shown in Figure 5-3, when the compressor/fuel pump motor is on, fuel isdrawn from the tank through the fuel pump and pressurizes the high pressureside of the fuel regulator. The fuel regulator reduces the fuel pressure suppliedby the fuel pump to atmospheric pressure. Compressed air flowing through thenozzle creates a venturi or suction effect which siphons fuel from the regulator. Ifthe compressed air flow through the nozzle stops, the regulator closes, shuttingoff the fuel flow.

Also shown in Figure 5-3 is the electrode and the flame sensor. The electrodeprovides the spark to ignite the fuel and the flame sensor is an optical devicewhich “sees” the flame.

1 Start

5.1.2

Fuel System – Step 1

Check: Fuel and fuel supply

a) The PROHEAT operation when supplying fuel from a directsource.

Test Procedure — Supplying fuel from a remote source:

a) Remove the fuel supply line from the outlet of the fuelregulator.

b) Put this end of fuel into a small container of CLEAN fuel that isabout the same level as the regulator centre similarly to Figure5-4. This will remove the vehicle fuel supply, fuel pump andregulator from the fuel delivery.

b) Switch the PROHEAT on and operate for at least 90 seconds.Observe the operation.

If the PROHEAT functions correctly, the fault is with the regulator,fuel supply or fuel pump. Check fuel lines, connections androuting back to fuel tank. Proceed to Step 2.

If a Start diagnostic code is indicated, the problem is with thenozzle or compressor fuel system. Proceed to Step 4.


Figure 5-3 Fuel System Schematic

AIRCOMPRESSOR

FUEL TANK

FUEL PICK-UP

NOZZLE

FUEL INLET

ELECTRODE

FLAME SENSOR

FUEL REGULATOR

FUEL PUMP

FUEL SUCTION

AIR FILTER

FUEL PRESSURE

COMPRESSED AIR

FUEL SUCTION



Check: Regulatora) For damage, contamination and mechanical operation.

Test Procedure — Vent Hole Regulator Style:a) Disconnect the fuel line at the nozzle fuel inlet fitting and place

in a container.

b) Inspect vent hole to ensure that it is not plugged.

c) Start the heater. No fuel should be exiting the outlet of theregulator.

If fuel is leaking from the outlet, replace fuel regulator.

Test Procedure — Capped Style:a) Remove fuel line that goes from the outlet of the regulator to

the nozzle.

b) Start the heater. No fuel should be exiting the outlet of theregulator.

If fuel is leaking from the outlet, replace the fuel regulator.

c) Install clear plastic hose that replaces the hose removed.

d) Start the heater. Fuel should start to flow out of the regulatorand up to the nozzle.

If the regulator does not operate as described in d), replace theregulator.

PLACE THIS LINE IN ACONTAINER OF FUEL

MAINTAIN FUEL LEVELAT CENTRE OF THEREGULATOR

REMOVE FUEL LINEFROM REGULATOR

Figure 5-4 Eliminating Fuel Pump and Regulator from system.



Check: Vehicle Fuel Supply, Fuel Pump

a) Vehicle fuel level and/or for fuel gelling during cold weather.

b) Air leaks and/or restrictions in the fuel supply lines to thePROHEAT.

c) The PROHEAT operation when supplying fuel from a directsource.

Test Procedure — Fuel Supply Inspection:

a) Is there fuel in the tank?

b) Check fuel lines, connections and routing back to the fuel tankfor kinks, loose fittings, stiff lines or cuts.

Replace any fuel lines that are cut, brittle or chaffed.

Test Procedure — Fuel Pump Inspection:

a) Disconnect the fuel line at the inlet to the regulator and placeinto a cup.

b) Start PROHEAT. Ensure that fuel flows out of the fuel line in asteady, uninterrupted and clear stream of fuel.

c) If fuel does not flow, check filter and relief valve for contaminationas per Service Bulletin SB0062. (See appendices page 7-1.)

Figure 5-5 Compressor / Fuel Pump Assembly

A

B

C

COMPRESSOR

DRIVE COUPLING X 2

FUEL PUMP

RELIEF VALVE

BOLTS X 2

INLETFITTING

PRESSUREADJUSTING SCREW

“O” RING

FILTER

OUTLETFITTING

ADAPTER

A• Apply Loctite 242 to threads• Torque bolts (2) to 25±3 in/lbs(2.8±0.3 Nm).

B• Lubricate o-ring with diesel fuel• Torque relief valve to 22±2 in/lbs(2.5±0.2 Nm).

C• Apply Loctite 59241 sealant tothreads.

• Torque elbow (1) to 55±5 in/lbs(6.2±0.5 Nm) minimum or untilelbow is at correct orientation.

NOTICE



Check: Air Compressora) Air compressor pressure and operation

Test Procedure — Air Compressor pressure:a) Run heater until warm to the touch. This ensures the heater

components are up to normal operating temperature.

b) Switch heater off.

c) Install PK0037 Digital Manometer (or a calibrated PK0060Analog Air pressure gauge) in-line as shown in Figure 5-6.

HOSE TONOZZLE AIR

INLET

DIGITALMANOMETER

PK0037

HOSE FROM COMPRESSOR

Figure 5-6

d) Locate the rubber boot on the positive end of the ignition coiland peel it back to expose the positive terminal.

e) Select the DC Volts range of a multimeter and connect as perFigure B. The positive lead of the multimeter should beattached to the positive coil lead. The negative lead of themultimeter should be attached to the heater chassis at thePROHEAT ground boss.

f) With the heater running in full output (flame on and ignition isoff) read the voltage and refer to the 12 or 24 volt chart (Figure5-8 and Figure 5-9) for the correct Air Pressure Reading.

g) The reading must be within the range of the shaded area asshown in Figure 5-8 and Figure 5-9.

NOTICEIf using PK0060, Analog Air pressuregauge, calibrate gauge before eachuse refer to:www.proheat.com/PDFs/990614.pdf

NOTICEAltitude Correction is needed above3000 Feet (see inset on charts).DO NOT adjust air pressure whenabove 6000 Feet.

NOTICERemove Pressure Gauge when finishedwith measuring & setting procedure.

WARNINGShock hazard due to high secondarycoil voltage.


Figure 5-7

10.5 11 11.5 12 12.5 13 13.5 145.8

6

6.2

6.4

6.6

6.8

7

7.2

7.4

7.6

AirPressure(PSI)

Operational Coil Voltage (V)

12V Proheat X45Air Pressure Range vs. in Operation Coil Voltage for a Warm Compressor

ACCEPTABLE RANGE

ACCEPTABLE RANGE

ACCEPTABLE RANGE

Figure 5-8 12V System Air Pressure Chart

21.521 22 22.5 23 23.5 24 24.5 25 25.5 26 26.5 275.8

6

6.2

6.4

6.6

6.8

7

7.2

7.4

7.6

AirPressure(PSI)

Operational Coil Voltage (V)

24V Proheat X45Air Pressure Range vs. in Operation Coil Voltage for a Warm Compressor

ACCEPTABLE RANGE

ACCEPTABLE RANGE

ACCEPTABLE RANGE

Figure 5-9 24V System Air Pressure Chart


Air Pressure ChecksIf Air Pressure is outside the range for the measured voltage please performthe following checks before adjusting the compressor:

Low Pressure Reading – Check:

i) Inspect air line from compressor outlet to fan end inlet for leaks, kinks orother restrictions.

ii) Check condition of air compressor filter. Retest with the filter removed.

High Pressure Reading – Check:

i) Nozzle and cavity for blockage. Refer to Step 5 on page 5-12.

ii) Compressor is out of adjustment.

Compressor AdjustmentAfter performing the above checks and the Air Pressure is still outside therange for the measured voltage Adjust the air pressure by turning the screwas shown in Figure 5-10. Altitude Correction is needed above 3000 Feet (seeinset on charts).

DO NOT adjust air pressure when above 6000 Feet.

COMPRESSOR

END VIEW OFADJUSTMENT SCREW:

DECREASEPRESSURE

INCREASEPRESSURE

ADJUSTMENTSCREWELECTRICAL

MOTOR

FUEL PUMP

Figure 5-10 Compressor / Fuel Pump Assembly

If the air compressor pressure cannot be adjusted back into normal range,replace air compressor.


NOTICEFuel Nozzle parts are a matched setand not interchangeable.

NOTICEDO NOT use a tip cleaner in the fuelorifice


Check: Nozzle

a) For fuel nozzle and o-ring damage and/or contamination.

Test Procedure — Fuel Nozzle Removal, Inspection & cleaning or replacement:

a) Remove three (3) bolts from the fan end and open up heater.

b) Remove nozzle from fan end.

c) Disassemble, inspect, clean and reassemble Fuel Nozzle(Figure 5-12).

Fuel Nozzle disassembly, inspection, cleaning & reassembly:

• Hold the Fuel Nozzle stem lightly but firmly in a vise usingsoft jaws, take care not to cause damage. Disassemblesin three pieces.

• Inspect Fuel Nozzle stem and O-ring for contamination and/ordamage. Inspect and clean distributor fuel orifice (a softbristled brush may be used), air passages, head and stemwith electrical contact cleaner or warm soapy water.

• Re-clamp the Fuel Nozzle stem lightly but firmly in a viseusing soft jaws, take care not to cause damage. Reinstallthe distributor and Fuel Nozzle head. Ensure that thedistributor is seated correctly. The Fuel Nozzle assembly isself-aligning. Torque to 30±3 in/lbs (3.4±0.3 Nm).

d) Inspect the Fuel Nozzle cavity and clean as necessary usingelectrical contact cleaner or warm soapy water

e) Reinstall Fuel Nozzle into the fan end using diesel fuel tolubricate the o-ring. Torque to 150±10 in/lbs (17±1.1 Nm).

f) Reinstall fan end and torque three (3) bolts to 75±5 in/lbs(8.5±0.5 Nm)

Figure 5-11. Nozzle Number Location

FUEL NOZZLEORIFICE

AIR PASSAGES

AIR PASSAGES

FUEL AND AIR OUTLET ORIFICE

HEAD

DISTRIBUTOR

STEM

O-RING

NOZZLENUMBER

TORQUE = SEESECTION 1.3

LUBRICATEO-RING WITHDIESEL FUEL

HOLD UPRIGHTTO ASSEMBLE

ARROWSSHOW HOW TOLOOSEN THE

NOZZLE

Figure 5-12 Fuel Nozzle Assembly


Ignition System

Check: Ignition Coil and Electrode Gap

a) Electrode cleanliness.

b) Electrode positioning for proper gap.

Test Procedure — Ignition System and Electrode Spark Inspection:

a) Inspect high tension lead between the coil and the electrode.Ensure that there is a proper connection at both the coil(positive and negative terminals) and at the electrode.

If the high tension lead is cut or damaged, replace.

b) Remove three (3) bolts from the fan end and open up heater.

c) Check the electrode for carbon buildup and clean as required.

d) Check electrode gap as per Figure 5-13.

e) Reinstall fan end and torque three (3) bolts to 75±5 in/lbs(8.5±0.5 Nm).

WARNINGThe PROHEAT chassis is grounded tothe PCM as shown in Figure 5-14.Ensure that the ground is securelyconnected. Failure to ensure aproper ground may result inelectrical shock.

Figure 5-13 Electrode Gap Detail

COMBUSTORTUBE

ELECTRODE

1/4" - 9/32"

Figure 5-14 PROHEAT Ground Boss

CHASSIS GROUND BOSS

GROUND WIREFROM PCM


Flame Sensor

Check: Flame Sensor

a) Flame sensor operation.

Test Procedure — Flame Sensor Circuit:

a) Check cleanliness of the flame sensor.

b) To test flame sensor for operation:

Spare Flame Sensor Available – Check:

i) Ensure unit is powered off. Disconnect flame sensor.

ii) Connect known good Flame Sensor to harness.

iii) Hold up known good Flame Sensor to Inspection Port.

iv) Start heater with the known good flame sensor held toInspection Port.

If heater runs for at least 90 seconds with the known good flamesensor, replace flame sensor as it is faulty.

Spare Flame Sensor Not Available – Check:i) Ensure unit is powered off. Disconnect flame sensor.ii) Shine incandescent flashlight directly at sensor.iii) Start heater with a flashlight shined directly at the sensor.iv) Code 6 should be displayed immediately on start up.

If Code 6 does not display immediately on start up, replace flamesensor as it is faulty.

NOTICEIf the lens is dirty, the sensor doesnot properly “see” the flame.

NOTICEDO NOT use an LED flashlight. Onlyan incandescent flashlight will checkthe sensor operation.


Indicates that a flame was detected (started successfully for at least 60 seconds)but is unable to maintain a steady flame before reaching the cycle offtemperature of 185°F (85°C).

Flame Out sequence:a) A flame is detected during the Ignition period and during Full Output.b) The flame goes out or fails to be detected.c) The ignition is switched on for a maximum of 10 seconds to try and

reestablish the flame.d) If the flame is not detected within 10 seconds, the Flame Out diagnostic

code is displayed.e) The PROHEAT goes into Cool Down (Purge) mode and attempts to restart

after Cool Down (Purge) is complete.

A Flame Out diagnostic code distinguishes that:

a) A flame was detected therefore there was a spark and the Ignitionsystem works.

b) The flame was detected therefore the Flame Sensor works.

c) The fault is in the fuel supply system.

d) The Flame Sensor could be dirty.

Troubleshoot the Flame Out diagnostic code based on:

1 Fuel supply to the PROHEAT.Go to page 5-6 and perform Fuel Systems Steps 1 to 5.• Fuel tank pick-up.• Fuel fittings.• Fuel lines.• OEM supplied filters and check valves.

2 PROHEAT fuel and flame detection system.Go to page 5-7 through page 5-14 and perform Fuel Systems Steps 2 to5, Ignition System and Flame Sensor checks.• Fuel Supply Pump• Air Compressor – pressure• Fuel Regulator – dirty or clogged• Nozzle – dirty or clogged• Flame Sensor – dirty

3 Operational symptoms that may occur in conjunction with a Flame Out code.Go to page 5-37.• Combustion hesitation or coughing.• Backfiring.• Smoke.• Strong diesel fuel odor.

2 Flame Out


A COOLANT FLOW diagnostic code is displayed when the coolant temperaturereaches 185˚F (85˚C) in less than one minute after ignition. This indicatesthat the coolant flow is severely restricted or blocked. This feature aids indetecting coolant flow problems that can degrade the PROHEAT performance.

An in-line flow indicator is a valuable troubleshooting tool used to: (Figure 5-15)

a) Check the coolant flow and direction.

b) Check for air in the system.

c) Check for restrictions caused by the truck systemsie. Shuttle valves, manual valves, air operated valves.

Check: Coolant Flow

a) Coolant Lines: For restrictions and blockagesAre clamps tight?

b) Shut-off Valves: Ensure that shut-off valves are open andfunctioning properly.

c) Fittings: Fittings must be at least 1⁄2" NPT or larger.Avoid using 90˚ fittings where possible.

d) Coolant Flow Direction: The PROHEAT must be plumbed sothat the coolant pump is pumping the coolant in the samedirection as the engine coolant pump. The PROHEAT can beused when the engine is running.

e) Coolant Pump: Does the pump function properly? (page 5-27)

f) Coolant System Capacity: The coolant system must containat least 3 gallons (11 litres) of coolant. If the systemcontains less the coolant may reach 185°F in less than 1minute causing a COOLANT FLOW diagnostic code.

g) Sleeper Heater: Many OEM sleeper heaters are combinedwith an air conditioning system. The solenoid shut-off valveused to cut off coolant flow during the air conditioning mode,must be open when using the PROHEAT. (Refer to page 3-9.)

Figure 5-15 Flow Indicator – TK9002

SLEEPER FAN

OTHER POSSIBLELOCATIONS

FLOWINDICATOR

3 CoolantFlow

NOTICEIf the coolant system is contaminatedwith magnetic material, it may causethe impeller to stop turning.


An OVERHEAT diagnostic code is displayed when the overheat breaker hastripped, shutting the heater down. This occurs if the heater has been startedwith little or no coolant in the heat exchanger.

Check: Coolant Flow

a) Is there coolant in the system?

b) Determine if there is a blockage or air in the plumbing.

The compressor motor is wired in series with the overheat breaker. The breakercontains a normally closed thermo switch. When the thermostat reaches thepreset temperature of 286°F (141°C), the contacts OPEN shutting thecompressor and fuel pump OFF, instantly shutting the heater down. It cannotbe restarted until the breaker is manually reset.

To reset the breaker, remove the rubber cap covering the top of the overheatbreaker and press the red reset button on top. If the breaker will not reset, allowthe heater to cool.

Test Procedure:

a) Connect a multimeter (adjusted to measure resistance) to theoverheat breaker connector. (Figure 5-16.)The sensor should be normally closed. If the sensor hastripped the circuit should be open.

Figure 5-16 Overheat Sensor Test

RED RESET BUTTON PLUNGER

SPRING

POLARITYNOT IMPORTANT

4 Overheat

CAUTIONDo not reset the Overheat breakeruntil the cause of the overheatcondition has been determined.


A VOLTAGE diagnostic code indicates that the supply voltage to the heater isout of the normal operating range.

Voltage ranges:

12 Volt heater – 10.0 to 15.0 Volts

24 Volt heater – 20.0 to 30.0 Volts

Check: Vehicle Voltage

a) Heater voltage must be within the specified range. Seefollowing page for procedure to measure heater voltage.

NOTE: Bad connections may show good voltage under no load conditionsbut not under full load. With the heater “OFF,” measure the voltage.Then switch the heater “ON” and measure the voltage again. Ifthe voltage drop is more than one Volt, check the vehicle batteryconnections, harness and the power connection at the PCM.b) If the measured voltage is higher than the specified range

then check the voltage regulator on the vehicle.NOTE: If the vehicle batteries are marginal, starting the vehicle while the

heater is running may:a) Drop the voltage enough to cause a voltage error.b) Cause random component errors (brown out).

To reset the PCM, switch the heater “OFF” and then back “ON” at the dashON/OFF Switch. If the problem continues, load test the batteries to confirm theircondition. Each battery should be independently tested.

Current: Checking current draw is done at the power harness connectionson the batteries.1) Check current draw on the red POSITIVE wire with the heater

NOT running. Should read 50 to 100 mA.2) Check current draw on the red POSITIVE wire with the heater

running in full output, ignition “OFF.” For 12 V models, thecurrent should be 6.5 to 9.0 A (varies with input voltage). For24 V models, the current should be 2.0 to 6.0 A (varies withinput voltage).

3) Check current draw on the black NEGATIVE wire with theheater NOT running and the red POSITIVE wire disconnected.Should read 0 mA. This test is to confirm whether or notthere is a power leakage from the vehicle through the heater.

Heater Voltage MeasurementThe positive terminal of the ignition coil is always hot relative to the heaterchassis ground as long as power is connected to the heater. This is thesupply voltage to the heater.

Test Procedure:

a) Locate the rubber boot on the end of the ignition coil andpeel it back to expose the positive and negative terminals.

b) Select the DC Volts range of a multimeter and connect asper Figure 5-17. The positive lead of the multimeter shouldbe attached to the positive coil lead. The negative lead of themultimeter should be attached to the heater chassis at thePROHEAT ground boss. (Figure 5-17)

c) Read the voltage with the heater running or trying to run.

Normal Voltage Ranges

12 Volt heater – 10.0 to 15.0 Volts24 Volt heater – 20.0 to 30.0 Volts

5 Voltage


Figure 5-17 Heater Voltage Measurement

Component Faults:6 – Flame Sensor 9 – Compressor 12 – Blower7 – Temp Sensor 10 – Ignition Coil 13 – Sleeper Fan8 – Fuel Pump 11 – Coolant Pump 14 – Hour Meter

This section covers the individual heater components. In many casesthere is a corresponding indicator light on the PCM function display. Theindicator light only indicates an electrical problem, NOT a mechanical failure.Component problems can also cause Function diagnostic codes.

A FLAME SENSOR diagnostic code indicates an electrical short circuit in theflame sensor wiring or a flame sensor failure. In addition, it can also indicatein rare cases the flame sensor detected a flame during pre-check (see Modesof Operation Section). It will not indicate an open circuit. The flame sensor isan optical device which “sees” the flame. If the sensor lens is dirty or has anopen circuit, it can not “see” the flame and results in either a START or aFLAME OUT diagnostic code to display.

Check: Flame Sensor

a) Inspect the flame sensor wiring for a short circuit.

b) Inspect the flame sensor lens for cleanliness.

c) Test the flame sensor. (See following page for flowchart,Figure 5-18.)

COMPONENT DIAGNOSTICS

6 FlameSensor

5.1.3

NOTICEA SLEEPER FAN error (13) and HOURMETER error (14) will not shut thePROHEAT down and heat to the enginewill be maintained.


Flame Sensor Test ProcedureStart Unit

Stop Unit

DisconnectSensor/Start Unit

Check Main Harnessfor a Short Circuit/Replace if necessary

Try with New PCM/Replace if necessary

Check Flame Quality

Check IgnitionSystem

Page 5-15

ReplaceSensor

ReplaceSensor

SensorOK

Check main Harnessfor Open Circuit/

Replace if necessary

Try with New PCM/Replace if necessary/After 60 Seconds ifthere is a Start Errorgo to Fuel System

Check FuelSystem

Page 5-27

Clean Sensor if necessaryand Restart

Disconnect OldSensor/Connect TestSensor/Hold up to

Inspection Port/Restart

Start Unit

Stop Unit

DisconnectSensor/Start Unit

Check Main Harnessfor a Short Circuit/Replace if necessary

Try with New PCM/Replace if necessary

Is therea Flame

Sensor Code?

Is therea Flame?

Is therea Spark?

Check Flame Quality

Check IgnitionSystem

page 5-13

ReplaceSensor

ReplaceSensor

SensorOK

Check main Harnessfor Open Circuit/

Replace if necessary

Try with New PCM/Replace if necessary/After 60 Seconds ifthere is a Start Errorgo to Fuel System

Check FuelSystempage 5-6

Clean Sensor ifnecessary and Restart

Disconnect OldSensor/Connect TestSensor/Hold up to

Inspection Port/Restart

After 60Seconds is therea Start Code?

Is therea Flame

Sensor Code?

After 60Seconds is therea Start Code?

Yes

Yes

Yes

Yes

NoYes

1

2

1

2

1

2

Yes

No

No

No

No

No

Figure 5-18 Flame Sensor Test Procedure Flow Chart


A TEMP SENSOR diagnostic code indicates a short or open circuit in thetemperature sensor wiring or the coolant temperature is out of range—below-58˚F (-50˚C) or above 266˚F (130˚C). The resistance of the temperaturesensor is proportional to temperature.

Check: Temperature Sensor (CODE indicated)

a) Inspect wiring for short or open circuits.

b) Check resistance of sensor. Is it within range as shown inFigure 5-20. If it is within valid range and the PCM stilldisplays code on start up, replace PCM.

C) Test the sensor. (See test procedure below.)

Test Procedure:

a) Connect a multimeter (adjusted to measure resistance) to thetemperature sensor as per Figure 5-19. The polarity of thesensor connections to the multimeter is not important.

b) Measure the sensor resistance versus temperature underthe following conditions:• at room temperature• in a freezer• in boiling water.

c) Compare the measured values against the graph (Figure 5-20).If values do not approximately match, then the sensor isdefective and must be replaced.

Figure 5-19 Temperature Sensor Test

7 TempSensor


Figure 5-20 Coolant Temperature Sensor Graph

400 600 800 1000 1200 1400 1600 1800 2000 2200

-60˚

-50˚

-40˚

-30˚

-20˚

-10˚

0˚

10˚

20˚

30˚

40˚

50˚

60˚

70˚

80˚

90˚

100˚

110˚

120˚

130˚

140˚

150˚

Temperature

Centigrade(°C)

Temperature

Farenheit(°F)Code07

Code07

-70˚

-40˚

-10˚

20˚

50˚

80˚

110˚

140˚

170˚

200˚

230˚

260˚

290˚

Resistance Ohms ( )

1354 65˚ C (150˚ F) LOWER SET POINT

VALID TEMPERATURE SENSOR RANGE

1541 85˚ C (185˚ F) UPPER SET POINT

2023 130˚ C (266˚ F) OUT OF RANGE (UPPER LIMIT)

515 -50˚ C (-58˚ F) OUT OF RANGE (LOWER LIMIT)

NOTE: Room temperature 70˚F (20˚C) Resistance 950ΩBoiling water 212˚F (100˚C) Resistance 1700Ω


The X45 fuel gear pump is driven by the same motor as the compressor.Therefore, there is NO fuel pump electrical diagnostic code. A FUEL PUMPdiagnostic code would indicate a fault in the PCM only.

A short or open circuit fault in the motor that drives the fuel pump will beindicated by a COMPRESSOR diagnostic code.

8 Fuel Pump

A COMPRESSOR diagnostic code indicates an open circuit in the wire harness, ashort in the wire harness between the positive and negative leads or an internalshort in the motor. This component is ground side switched in the PCM.

Symptom: Air Compressor not running (code indicated)

Check: Air Compressor wiring & functiona) That compressor is connected to harness correctly.

(See PROHEAT Wiring Diagram page 1-4)b) The connector pins for damage or corrosion.c) Harness for pinched or abraded wires.d) Test compressor. If it tests OK replace PCM.

(See Figures 5-7 & 5-8 and Test Procedure)

Test Procedure:

a) Connect air compressor directly to a power sourceof the rated voltage (12/24 Volts) and see if the motor runs.If not, replace the compressor.

b) Measure air compressor motor resistance. Use a multimeterto measure the resistance across the compressor connectorpins. If resistance shows an open or short circuit, replace thecompressor assembly.

c) Measure air compressor current. Use test lead part #967921K,as described on Service Bulletin #967329 in the Appendix.

Figure 5-21 Compressor Test

MODEL CURRENT DRAW (Amps)

X45-12 3.50 - 5.00 @ 12 Volts

X45-24 1.50 - 3.00 @ 24 Volts

PRESSUREADJUSTINGSCREW

9 Compressor


Compressor Mechanical And Electrical Troubleshooting (No code Indicated)

The following material covers the air compressor mechanical or electrical problemsthat DO NOT indicate a Code 9. The compressor/fuel pump motor is groundside switched- there is always voltage at the positive terminal to the motor.

Symptom: Air Compressor runs as soon as power is applied (No codeindicated)

Check: Internal Short in Motor

a) Disconnect compressor/fuel pump motor from internal harness.

b) To check motor condition:

Spare Compressor Motor is Available – Check:

i) Connect spare motor to internal harness and apply powerto heater.

If spare motor does not run, replace the compressor/fuelpump motor. If the spare motor still runs:

ii) Inspect internal harness wires going to compressor.Ensure that there is no chaffing or cuts that would providea compressor motor ground short.

If internal harness is in good condition, replace PCM.

Spare Compressor Motor is not Available – Check:

i) Plug connector that normally goes to compressor motorinto the blower.

If the blower does not spin when power is applied, thisindicates that there is a short in the compressor motor orshort in the internal harness. Verify root cause by checkingSteps (ii) and (iii).

If the blower spins, this indicates that there is a fault withthe PCM or there is a short in the internal harness. Verifyroot cause by checking Step (iii).

ii) Measure resistance between either pin on the connectorgoing to the motor and the body of the heater

If the resistance is not in the mega-ohm range, replace thecompressor/fuel pump motor.

If the resistance is in the mega-ohm range, go to Step (iii).

iii) Inspect internal harness wires going to compressor.Ensure that there is no chaffing or cuts that would providea motor ground short.

If internal harness is good condition, replace PCM.


An IGNITION COIL diagnostic code indicates an open circuit in the wireharness, a short in the wire harness between the positive and negative leadsor an internal short in the coil. The fuse will blow if there is a short to groundin the positive lead or the coil. The ignition coil is the easiest place tomeasure the voltage on the heater. This component is ground side switchedin the PCM.

Symptom: No spark at the electrode (code indicated)

Check: Coil wiring

a) Inspect the wiring harness to ensure the ring terminals aresecured to the coil. Make sure the polarity is correct.

b) Inspect for broken or abraded wires in the wire harness.

b) Test coil. (Figure 5-23.)

c) If an IGNITION COIL diagnostic code occurs and no fault isfound in the coil and wiring, then the PCM must be checked.

Symptom: Air Compressor running (No code indicated)Fuse blown in PCM

Check: Air Compressor operation

a) Harness for pinched or abraded wires. The positive wire mustnot short to ground.

b) Motor for internal short. (See Figure 5-21 and Test Procedure)

c) Check for seized motor or fuel pump. (See Figure 5-5 andFigure 5-22)

REMOVE FOUR BOLTS ANDCOVER FOR ACCESS TO THECOMPRESSOR COUNTERWEIGHT BY HAND TOCHECK FOR SEIZED MOTOROR FUEL PUMP.

Figure 5-22 Compressor Access Cover

10 IgnitionCoil

WARNINGThe PROHEAT chassis is groundedfrom the PCM as shown in Figure5-14. Ensure the ground is securelyconnected. Failure to ensure aproper ground may result inelectrical shock.

WARNINGDisconnect the PCM electricalpower prior to trying to turn thecompressor counterweight byhand.


Figure 5-23 Ignition Coil Test

Ignition Coil Electrical Troubleshooting (No code Indicated)

The following material covers the ignition coil mechanical or electrical problemsthat do not indicate a Code 10. The ignition coil is ground side switched —there is always voltage at the positive terminal to the ignition coil.

Symptom: No spark at the electrode (No code indicated)

Check: High tension wires and electrode

a) Inspect the high tension lead between the coil and theelectrode.

b) Inspect the ground lead between the second electrode andthe heater chassis.

c) Is the electrode gap adjusted correctly? (See page 5-13 forElectrode Gap Detail)

Test Procedure:

a) Measure ignition coil resistance. Use a multimeter to measurethe resistance across the positive and negative terminals.The resistance should be less than 1 ohm. If resistance is“open circuit” or 0 ohms (short circuit) then replace theignition coil.

NOTE: Remove positive and negative wires from the coil when testing.


A COOLANT PUMP diagnostic code indicates an open circuit in the wireharness, a short in the wire harness between the positive and negative leadsor an internal short in the motor. This component is ground side switched inthe PCM.

The coolant pump is not self-priming. Ensure that the coolant system hasbeen purged of air by running the vehicle engine for at least ten minutesfollowing installation or service. (DO NOT run dry.)

Symptom: Pump not running (code indicated)

Check: Pump Motor

a) Connect coolant pump directly to the rated voltage(12/24 Volts) and see if it runs. If not, replace the pump.

b) Measure coolant pump motor resistance. Using amultimeter, measure the resistance across the coolant pumpconnector pins. If resistance shows an open circuit or aninternal short circuit, replace the coolant pump.

c) Measure coolant pump current. Use test lead part #967921Kas described on Service Bulletin #967329 in Appendix.

11 CoolantPump

Figure 5-24 Coolant Pump Test


X45-12 1.50 - 4.00 @ 12 Volts

X45-24 0.75 - 2.00 @ 24 Volts


Symptom: Coolant pump not running (code indicated)

Check: Coolant Pump wiring & function

a) That coolant pump is connected to harness correctly.(See PROHEAT Wiring Diagram page 1-4)

b) The connector pins for damage or corrosion.

c) Harness for pinched or abraded wires.

d) Test pump. If it tests OK replace PCM.(See Figure 5-24 and Test Procedure.)

Coolant Pump Mechanical & Electrical Troubleshooting (No code Indicated)

The following material covers the coolant pump mechanical or electrical problemsthat do not indicate a Code 11. The coolant pump motor is ground side switched— there is always voltage at the positive terminal to the motor.

Symptom: Coolant pump runs as soon as power is applied (No code indicated)


a) Disconnect coolant pump motor from internal harness.


Spare Coolant Pump is Available – Check:

i) Connect spare coolant pump motor to internal harnessand apply power to heater.

If spare coolant pump does not run, replace the coolantpump. If the spare coolant pump still runs:

ii) Inspect internal harness wires going to coolant pump.Ensure that there is no chaffing or cuts that would providea coolant pump motor ground short.


Spare Coolant Pump is not Available – Check:

i) Plug connector that normally goes to coolant pump motorinto the blower.

If the blower does not spin when power is applied, thisindicates that there is a short in the coolant pump motor orshort in the internal harness. Verify root cause by checkingSteps (ii) and (iii).

If the blower spins, this indicates that there is a fault withthe PCM or there is a short in the internal harness. Verifyroot cause by checking Step (iii).

ii) Measure resistance between either pin on the connectorgoing to the coolant pump motor and the body of the heater.

If the resistance is not in the mega-ohm range, replace thecoolant pump.


iii) Inspect internal harness wires going to coolant pump.Ensure that there is no chaffing or cuts that would providea motor ground short.

If internal harness is good condition, replace PCM.


Symptom: Coolant pump not running (no code indicated)Fuse blown in PCM

Check: Coolant Pump function

a) Harness for pinched or abraded wires. Positive leadmust not short to ground.

b) Check motor for internal short.(See Figure 5-24 and Test Procedure.)

Symptom: Coolant pump not pumping (no code indicated)

Check: Coolant Pump function

a) If the impeller is turning freely. If not, replace pump.

Symptom: Coolant pump leaking

Check: Leak location

a) Hose clamps. Tighten if necessary.

b) Pump housing seal. Replace pump if required.


A BLOWER diagnostic code indicates an open circuit in the wire harness, a shortin the wire harness between the positive and negative leads or an internalshort in the motor. This component is ground side switched in the PCM.

The PCM measures the RPM of the blower. This feature will give an error shouldit fall below the necessary RPM to maintain sufficient combustion air.

Symptom: Blower not running (code indicated)

Check: Blower wiring & function

a) That blower is connected to harness correctly.(See PROHEAT Wiring Diagram page 1-4)

b) The connector pins for damage or corrosion.

c) Harness for pinched or abraded wires.

d) Test blower. If it tests OK replace PCM.(See Figure 5-25 and Test Procedure)

Blower Mechanical and Electrical Troubleshooting (No code Indicated)

This section covers the blower mechanical or electrical problems that do notindicate a Code 12. The blower motor is ground side switched — there isalways voltage at the positive terminal to the motor.

Symptom: Blower runs as soon as power is applied (No code indicated)


a) Disconnect blower motor from internal harness.


Spare Blower is Available – Check:

i) Connect spare blower to internal harness and apply powerto heater.

If spare blower does not run, replace the blower pump. If thespare blower still runs:

ii) Inspect internal harness wires. Ensure that there is nochaffing or cuts that would provide a blower motor groundshort.


Spare Blower is not Available – Check:

i) Plug connector that normally goes to blower motor intothe coolant pump.

If the coolant pump does not spin when power is applied,this indicates that there is a short in the blower motor orshort in the internal harness. Verify root cause by checkingSteps (ii) and (iii).

If the coolant pump spins, this indicates that there is a faultwith the PCM or there is a short in the internal harness.Verify root cause by checking Step (iii).

ii) Measure resistance between either pin on the connectorgoing to the blower motor and the body of the heater

If the resistance is not in the mega-ohm range, replace theblower.


12 Blower

CAUTIONWhen a blower fails, the combustionchamber must be checked for carbonbuild up and cleaned as necessary.


Figure 5-25 Blower Test


X45-12 .75 - 1.5 @ 12 Volts

X45-24 .5 - 1.0 @ 24 Volts

iii) Inspect internal harness wires going to blower. Ensurethat there is no chaffing or cuts that would provide ablower motor ground short.

If internal harness is good condition, replace PCM

Symptom: Blower not running (no code indicated)Fuse blown in PCM

Check: Blower function

a) Harness for pinched or abraded wires.Positive lead must not short to ground.

b) Check motor for internal short.(See Figure 5-25 and Test Procedure)

Symptom: Blower turning slowly (no code indicated)

Check: Blower function

a) For fan blade rubbing on housing.

b) For fan blade slipping on motor shaft.

Test Procedure:

a) Connect the blower to a power supply of the rated voltage.Does it turn? If not, replace the blower.

b) Measure the blower motor resistance. Using a multimeter,measure the resistance across the blower connector pins. Ifresistance shows an open circuit or an internal short circuit,then replace the blower assembly.

c) Measure blower current. Use test lead part #967921K asdescribed on Service Bulletin #967329 in Appendix.


A SLEEPER FAN diagnostic code indicates an electrical short in the sleeperfan wiring harness, electrical connections or fan motor. This error will notshut the heater down and heat to the engine will be maintained. An opencircuit will not display a diagnostic code.

NOTE: This error is only applicable to "Sleeper Fan" models. See page 4-2 formodel identification. If the PCM model is an "Aux Input" model andthis error is displayed, there is a fault with the PCM. Replace the PCM.

Symptom: Sleeper Heater fan not turning (code indicated)

Check: Sleeper Heater system

a) The wiring connections and polarity.

b) For an electrical short from the positive wire to the negativewire. For an electrical short from the positive wire to thechassis. Test sleeper heater fan. (See Test Procedure)

Sleeper Fan Troubleshooting (No code Indicated)

The following material covers the sleeper fan mechanical or electricalproblems that do not indicate a Code 13. Note that the sleeper fan is highside switched.

Symptom: Sleeper Heater fan not turning (no code indicated)



b) Test sleeper heater fan. (See Test Procedure)

Symptom: Sleeper Heater system has low air flow (no code indicated)


a) Air ducting.

b) Use Test Procedure items (e) and (f) to determine if PROHEATis supplying enough power to drive the sleeper fan.

Test Procedure:

a) Disconnect sleeper fan harness.

b) Restart the PROHEAT, If there is still an error, replace the PCM.

c) Check for correct voltage at the sleeper fan output on thePCM. (See wiring diagram on page 1-4 and page 1-5.)

d) Reconnect sleeper fan harness. Start the PROHEAT.

e) Check for voltage at the thermostat, isolator (if used) and thesleeper fan motor. The power to the sleeper heater fan isregulated by voltage in the PCM. It will read low when tryingto drive the sleeper fan.

f) Connect sleeper heater fan motor directly to a remote powersource of the rated voltage (12/24 Volts). Does the motor run?

13 SleeperFan

NOTICEThe PROHEAT PCM sleeper fancircuit has a one minute delayduring ignition. Power to open asleeper fan coolant valve must betaken from another source such asthe wire for the Hour Meter (AuxiliaryOutput). (See PROHEAT WiringDiagram page 1-4.)

SECTION 5. TROUBLESHOOTING & REPAIR


An HOUR METER (AUXILIARY OUTPUT) diagnostic code indicates an electricalshort in the hour meter (auxiliary output) wiring harness, electrical connectionsor connected electrical load. The electrical load could be an hour meter, relayor any other low load (< 1 A) connection that depends on the installation. Thiserror will not shut the heater down and heat to the engine will be maintained.An open circuit will not display a diagnostic code.

Symptom: Hour Meter (Auxiliary Output) Electrical Load not Operating(code indicated)

Check: Hour Meter (Auxiliary Output) Electrical Load


b) For an electrical short from the positive wire to the negativewire. For an electrical short from the positive wire to thechassis. Test electrical load. (See Test Procedure)

Hour Meter Troubleshooting (No code Indicated)

The following material covers the Hour Meter (Auxiliary Output) electrical problemsthat do not indicate a Code 14. Note that the Hour Meter (Auxiliary Output) ishigh side switched.

Symptom: Hour Meter (Auxiliary Output) Electrical Load not Operating (nocode indicated)

Check: Hour Meter (Auxiliary Output) Electrical Load


b) Test electrical load. (See Test Procedure)

Test Procedure:

a) Disconnect load/circuit to hour meter (auxiliary output) harnessand start heater. If error goes away, check for short circuitsin the load/circuit.

b) Restart the PROHEAT. If there is still an error, disconnectthe 18-pin internal harness and restart the PROHEAT again.If code 14 is still present, replace PCM.

c) Check for correct voltage (12 V: 9 – 14 V, 24 V: 19– 30 V) atthe hour meter (auxiliary output) harness.

d) Reconnect hour meter (auxiliary output) harness. Start thePROHEAT.

e) Connect electrical load directly to a remote power source ofthe rated voltage (12/24 Volts). Does the electrical load run?

14 HourMeter

(AuxiliaryOutput)

Figure 5-26 Hour Meter (Auxiliary Output) Test


COMPONENT MECHANICAL ORELECTRICAL PROBLEMS

5.2

FUEL NOZZLE

Go to page 5-12.

5.2.1

FUEL REGULATOR

Go to page 5-7.

5.2.2

AIR COMPRESSOR

Go to page 5-9 and page 5-23.

5.2.3

FUEL PUMP

Go to page 5-8.

5.2.4

IGNITION ELECTRODE

Go to page 5-13.

5.2.5

COOLANT PUMP

Go to page 5-27.

5.2.6

BLOWER

Go to page 5-30.

5.2.7


FUSE

If, when the heater is switched “ON,” the heater does not run and the “ON”light does not light, check the fuse in the PCM. The fuse will blow if there is ashort to ground in a positive lead or internally for the following components:

• ON/OFF Switch • Coolant Pump

• Air Compressor/Fuel Pump • Blower

• Ignition Coil • Internal Wire Harness

Reversing polarity at the battery will also cause the fuse to blow. This will notharm the PCM.

Check: Heater wiring. See flow chart Figure 5-28 on next page.

Figure 5-27 Internal Wire Harness Test

FED

CBA

3 2 1

3 2 1

HARNESS TO COMPONENTS

PIN LOCATIONS MOLDED INTO CONNECTOR

COIL

COOLANT PUMP

COMPRESSORBLOWER

GROUND ONHEAT EXCHANGER

FUSE

CAUTIONRepeated replacement of the fuseor using incorrectly rated fuseswithout correcting the problem,can damage the PCM.

5.2.8


Fuse Blown Test Procedurewith Power Connected andPROHEAT Switched “OFF”

Check for correct battery polarity

Replace PCM Reconnect Internal Wire Harness(18 Pin Connector)

Yes No

Remove Fuse

Replace Fuse(15 amp only)

DoesFuseBlow?

ReplaceInternal

Wire HarnessReconnect Components

One at a time

Yes NoDoesFuseBlow?

Check Component as perTroubleshooting Guide

Component OK

Yes NoDoesFuseBlow?

Disconnect all components fromInternal Wire Harness

(10 Connections) (See NOTE)

Reconnect Switch Harness

Yes NoDoesFuseBlow?

Check Switch Harnessand Connectionsfor Short Circuit

Harness OK

Yes NoDoesFuseBlow?

Disconnect from PCM:• Internal Wire Harness(18 Pin Connector)• Switch Harness

NOTE: Ensure positive wire fromthe PCM to the ignition coildoes not ground.

NOTE: A short circuit in the sleeperfan outlet and hour meter(auxiliary output) harnesswill not blow the fuse. Anerror will be indicated onthe PCM. This will not shutthe heater down.

Figure 5-28 Blown Fuse Test Procedure Flow Chart


Heater Operational Problems that are not specifically described in thefunction or component diagnostic section.

COMPLAINT: Smoking exhaust/Smelly exhaust fumes

These symptoms are usually an indication of an extremely rich air/fuel mixture.

a) Is the PROHEAT connected to the correct voltage? (page 5-18)

b) Is the blower functioning? Is the air inlet restricted?

c) Is the compressor functioning? (page 5-23)

d) Is the exhaust restricted?

e) Is it a new heater? New heaters may smoke for 15 minutes as oil isburned off the exhaust pipe.This is normal.

COMPLAINT: Low heat output

If the heater appears to be functioning properly but the driver complains oflow heat this is often indicative of a coolant flow restriction. (See section onCoolant Flow page 5-16).

COMPLAINT: Engine temperature gauge reads low

Depending on its location, the engine temperature sensor may not be directlyin the path of coolant flow from the heater. In these cases the gauge mayread significantly lower than actual coolant temperature.

COMPLAINT: Backfiring

Backfiring occurs when there is air in the fuel supply lines.

a) Fuel level in tank – is the pick-up submerged?

b) Air leaks – are all the fuel line clamps tight?

c) For severely restricted combustion air blockage at the blower inlet, in thecombustion chamber, or in the exhaust system.

OPERATIONAL PROBLEMS

Check

Check

5.3

5.3.1

5.3.2

5.3.3

5.3.4

SECTION 6. MAINTENANCE 6-1

MAINTENANCE6.0

Run the heater a minimum once a week to keep new fuel in the heater’scritical components.

ANNUAL MAINTENANCEYour PROHEAT has been designed to operate with a minimum of maintenance. Toensure the efficient operation of your heater an ANNUAL MAINTENANCE TUNE-UP is strongly recommended to be performed each year.

Proper maintenance will result in the following benefits:

• Maximum heat transfer to the coolant• Minimum battery power draw• Long term cost savings• Increased reliability

Check the system annually before each heating season. There are severalmaintenance procedures you can perform to keep your heater in service.Read this section of the manual carefully.

Always return to your Authorized PROHEAT Dealer for major maintenance.Your PROHEAT Dealer has the specialized equipment necessary to keep yourPROHEAT in new condition.

Figure 6-1 PROHEAT X45 Heater

NOTICEA higher duty cycle may require amore frequent maintenance schedule.i.e. 2 or 3 times per year.

WEEKLY MAINTENANCE6.1

6.2

CLEAN HEATER, ENCLOSURE AND AIR INTAKE

• Remove the heater enclosure cover.

• Clean any accumulated debris or dust from the components.

• Blow out the compartment with compressed air.

• Check the combustion air inlet screen for restrictions. Clean as required.

• Make sure the opening around the exhaust pipe is clear.

• Visually inspect all the components for wear or damage.

• Clean the X45 Heater using the following procedure.

1 Protect yourself from burns and only touch a heater after it has cooledto room temperature.

2 Clean the X45 Heater by hand with dry or damp cloth, or withcompressed air. DO NOT use chemical agents as this may damagesurfaces, gaskets, boots, cabling and/or hoses.

3 DO NOT use a pressure washer or hose down the heater. This mayresult in damage to the PCM or damage to the electrical system.

4 Water should not come into contact with any part of the heater when it ishot. Water can cause rapid cooling which may damage components.

5 Ensure that the rubber boots on the ignition lead are clean and freefrom debris. Remove debris with compressed air or by wiping with aclean towel. DO NOT use chemical agents on the rubber boots.

Figure 6-2 X45 Heater and Enclosure

AIR INLET SCREEN

ENCLOSURE

X45 HEATER

WARNINGDO NOT pressure wash or steamclean.


6.2.1

CHECK EXHAUST SYSTEM

• Make sure the exhaust pipeis vented safely away fromthe vehicle cab.

• Check the pipe for dents,restrictions or severelycorroded areas.

• Replace the exhaust pipeand clamps if necessary.

• Ensure the exhaust pipeclamp is tight.

• Clean exhaust pipe if there isa significant accumulationof carbon build up.

Figure 6-3 Exhaust Pipe

CHECK HEAT EXCHANGER

• To maintain optimum heat output, clean any combustion deposits that mayhave accumulated on the heat exchanger fins.

• Remove the fan end assembly and combustion tube to access the inside ofthe heat exchanger.

• Ensure exhaust pipe is clean and free from restriction.

• Use a wire brush to loosen the deposits and a vacuum to suck them out.

• Torque securing screws to 25±3 in/lbs (2.8±0.3 Nm).

Figure 6-4 Heat Exchanger

COMBUSTION TUBE

HEAT EXCHANGER FINS

SECURINGSCREWS

EXHAUST PIPE

6-3SECTION 6. MAINTENANCE

6.2.3

6.2.2

FLAME SENSOR

Figure 6-6 Test Battery

CHECK COOLING SYSTEM

• Check all heater hoses and connections for signs of leakage or damage.

• Repair or replace as required.

• NOTE: The coolant mix must be 50% Ethylene Glycol.

CHECK BATTERIES

• Check the condition of batteries andthe power connections.The heater will not function properlywith weak batteries or corrodedconnections.


6.2.5

CLEAN FLAME SENSOR

• To maintain proper sensor readings, the flame sensor glass should be

wiped clean.

• With the fan end removed, clean the sensor glass with water and a rag.

Glass should be clear.

6.2.4

6.2.6

Figure 6-5 Flame sensor

SECTION 6. MAINTENANCE

Figure 6-7 Fuel Line Clamp

HOSE CLAMP

GROMMET

FUEL LINE

AIR FILTER

FUEL FILTER

FUEL TANK

FUEL PICK UP

HOSE CLAMP

FUEL LINE

CHECK FUEL SYSTEM

• Check the fuel system for damaged fuel lines or leakage.

• Make sure the clamps on the fuel lines are secure.

• Ensure fuel lines are flexible.

CHECK FUEL FILTER

• Remove and inspectfilter. Clean or replaceas necessary.

O-RINGO-RING

FILTER

TORQUE TO150±10 IN/LBS(17±1.1 Nm)

Figure 6-8 Fuel Filter Components

6-5

6.2.8

6.2.7


Figure 6-9 Nozzle Components

CLEAN NOZZLE

BLOW THIS DIRECTIONWHEN USINGCOMPRESSED AIR.

TORQUE TO30±3 IN/LBS(3.4±0.3 Nm)

HOLDUPRIGHT TOASSEMBLE

REPLACE COMPRESSOR AIR FILTER

• Replace inlet air filter annually or more oftenif dusty conditions are encountered.

TORQUE TO 50±5 IN/LBS (5.6±0.7 Nm)

• Remove and install Nozzle as shown on page 5-12.Torque to 150±10 in/lbs (17±1.1 Nm).

• To properly clean the nozzle use electricalcontact cleaner or warm soapy water.This will wash any dirt out and leaveno residue. When using compressedair, blow into the nozzle orificefrom the head end.

Figure 6-10 Compressor Air Filter

6.2.10

6.2.9

SECTION 6. MAINTENANCE 6-7

CHECK ELECTRICAL SYSTEM

• Check the internal and the external wire harnesses for damage. Replace ifrequired.

• Service the X45 Ignition Lead and Ignition Coil by following the steps listedbelow.

1 Annually or better, inspect the ignition lead and the boots on both ends.Replace the entire lead with new lead (p/n 930523K) if the lead itself orboots are coated with oil, torn, cracked or brittle.

2 Ensure that the electrical connections are clean and tight.

3 Ensure that all boots are clean and free from debris. Remove debris bywiping with a clean towel. Do not use water or chemical agents.

4 Ensure that all boots are properly reseated.

• It is recommended that the ignition lead is replaced every five years orbetter with a new lead (p/n 930523K).

Figure 6-11 Wire Harnesses

CAUTIONEnsure that power is disconnectedto the X-45 prior to servicing theIgnition Lead.

IGNITION COILIGNITION LEAD

Figure 6-12 Ignition Coil

6.2.11


PART # QTY DESCRIPTION

825730K 1 Air Filter, X45.

880035K 1 Fuel Filter, X45.

PART # QTY DESCRIPTION

PK0094 1 X45 Fall Service Kitincludes:1 x Air Filter1 x Fuel Filter2 x O-Ring

PK0069 1 X45 Major Service Kit1 x Electrode1 x Nozzle1 x Regulator1 x Flame Sensor1 x Ignition Lead1 x Air Filter1 x Fuel Filter2 x O-Ring

Replacement Parts

CHECK MODES OF OPERATION – SWITCH, TIMER OROEM SIGNALS

• Check to see that the modes operate as described on page 4-5 to page 4-7.

Operation Test • Run the system for at least 15 minutes or until the heater cycles “OFF” andthen “ON” again.

• Alternate the thermostat for the sleeper heater (if connected) between thelowest and highest settings to ensure that the sleeper heater fan cycles“ON”and “OFF”.

6.2.13

CHECK AIR PRESSURE

• Refer to Air Compressor pressure test procedure on page 5-9.

6.2.12

Figure 6-13 Air Compressor pressure test procedure

HOSE TONOZZLE AIR

INLET

DIGITALMANOMETER

PK0037

HOSE FROM COMPRESSOR

COOLANT FLOW INDICATOR .......................................................... 951528K

TEST LEADS ................................................................................ 967329K

GROUND SIDE BATTERY DISCONNECT ............................................ SB0003

G-III PROHEAT CONTROL MODULE (PCM)FOR X45 AND XL SERIES HEATERS ................................................ PB0034

FUEL PUMP PRESSURE CHECK AND SERVICE ................................. SB0062

CONTENTS

APPENDICES7.0

7-1SECTION 7. APPENDICES

Description:Coolant Flow Indicator

Part:TK9002

Purpose:The Coolant Flow Indicator is aservice tool used to troubleshootand test for possible flow and airproblems in the coolant flow path.Flow direction during heateroperation or during engineoperation can then be observed.

FLOW INDICATORTK9002

FLOWINDICATOR

SLEEPER FAN

FIGURE 2

FLOW INDICATORTK9002

FIGURE 1

OTHER POSSIBLELOCATIONS

FLOW

© 1994 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Tel: 604.270.6899 Web: www.proheat.com

SERVICE BULLETINCopy Part# 951528, Rev. A, 10/1993 Page 1 of 1


SERVICE BULLETINCopy Part# 967329, Rev. A, 05/1994 Page 1 of 1

Description:The PROHEAT wiring system usessealed connectors for resistanceto corrosion and greater reliability.The following test leads arerequired for troubleshooting.

Parts:967921K Test Lead

952925K Remote On/Off switch

Instructions:1. Test Lead #967921K is used

for measuring voltage, resistance,continuity or amperage and canbe used on all componentsexcept for the blower. Directvoltage can be applied to thecompressor and water pumpby wiring from a remote powersource to the spade connections.

2. The #952925K Remote On/Offswitch allows the servicetechnician to plug into theheater at the switch inputof the PCM. This allows theheater to be turned On/Off atthe unit.

RED

BLACK

BA

A A B

USE SPADE CONNECTORS TOTEST VOLTAGE, RESISTANCEOR CONTINUITY

USED IN SERIES TO READ AMP

REMOTE ON/OFF SWITCH952925K

24 INCHES

FIGURE 1

FIGURE 2


SERVICE BULLETINCopy Part# SB0003, Rev. A, 06/1995 Page 1 of 2

Description: Ground Side Battery Disconnect

Purpose: This service bulletin includes troubleshooting steps and protectionrecommendations from damage, that may occur when attempting anengine start while the ground side battery disconnect switch is in the"open" position. A Proheat is typically connected directly to the batteriesso that it can be used to preheat the coolant when the ground side batterydisconnect switch is "open". If the operator (driver) attempts to start theengine with this switch "open" the entire electrical current from the startermotor attempts to pass through the proheat internal wiring harness.Without adequate fuse protection the Proheat ground circuit in the internalharness and/or controller will be damaged.

Test Procedure: The symptoms may include a START error or FLAME OUT error. The fuelpump will not operate if the Proheat ground circuit has been damaged,resulting in intermittent operation of the Proheat.

1. Start the Proheat. Check that the fuel pump is running. Approximately20 to 40 pulses per minute can be felt or heard. Check for voltage atthe fuel pump power terminal.

2. If the fuel pump does not operate, ground the body of the fuel pumpdirectly to the battery negative post using a wire. Restart the Proheat.If the fuel pump runs and the Proheat starts then the problem is in theground wire.

Note: It is possible to get a partial ground for the fuel pump if theexhaust pipe is contacting the machine frame and the groundside battery disconnect switch is closed.

3. To locate the fault in the ground circuit, first check the internalharness. The ground wire is black with a green stripe. Remove the 18pin connector from the controller and check for continuity between theground pin (Pin C3) and the ring terminal. See Figure 1 (over). If a faultis found replace the harness. Next, check the controller by measuringfor continuity between pin C3 on the controller 18 pin connector andpin B at the power harness connector. See Figure 2.

4. If the fuel pump did not run in step 2 refer to Fuel Pump, Start error andFlame Out error in the troubleshooting section of the Service Manual.

RecommendedMethod of Protection: 1. Install a 10 amp in-line fuse on the ground wire (black with green stripe)

of the Proheat harness. Proheat Part# PK0310.

2. Ensure that the Proheat exhaust pipe does not contact vehicle chassis.

3. If possible rewire the disconnect switch to the positive side of the battery.



GROUND RING TERMINAL

PIN C3

BLACK WITH GREEN STRIPEEND VIEW

FIGURE 1

FIGURE 2

Pin C3

3-A3-B

2-B2-C

2-A2-D

PIN1-B

1-A1-C

SLEEPER FAN 3-A POWER +12V/+24V (3 AMP LIMIT) 3-B GROUND (-)

SWITCH OUTPUT 2-A POWER +12V/+24V (OUTPUT) 2-B GROUND (-) 2-C "ON" SIGNAL (TO HEATER) 2-D INDICATOR +12V/+24VOLTS

POWER 1-A POWER +12V/+24V (IMPUT) 1-B GROUND (-) 1-C NOT USED


PRODUCT UPDATE BULLETINCopy Part# PB0034, Rev. B, 04/2009 Page 1 of 3

Application Discontinued ReplacementPCM PID PCM PID

X45-12 V Trucks with or without Sleeper Kit 903100K 999100Kand on Heavy EquipmentX45-12 V Transit or Coach 904200K 999200KX45-12 V School Bus 904300K 999300KX45-24 V Transit or Coach, Heavy Equipment 905300K 999400Kand School BusXL Bravo 24 V External Compressor 817526-1K 999600KTransit or CoachXL Bravo 24 V Internal Compressor 906300K 999700KTransit or CoachX45-24 V Coach MCI Custom 906400K 999800K

Introducing: G-III Proheat Control Module (PCM) for X45 and XL series Heaters.

Part Numbers:

Updates: 1. 100% backward compatible - no adapter required2. CANbus communication and new serial port location3. New 2x7 Segment LED4. Vent with filter

Figure 1: Example photo of newPCM (PID 999100 shown).



1 100 % Backward Compatible• G-III PCM works with existing heaters and wiring harnesses.

2 CANbus Communication and new Serial Port Location

• The new communication port provides CANbus SAE J-1939 communication.

• Relocated serial port allows Datalink connection without disconnectingthe switch input.

• New communication port requires the G-III controller Proheat Data LinkKit PK0053-3. The G-II download cable kit PK0053-2 (download cableand software) will not work with the G-III controller.

3 New 2x7 Segment LED

• The 2x7 segment LED provides improved communication of operationalstates and error messages.

• Figure 2: Original G-II PCM display with single LED lamps and new G-III PCMdisplay with 2x7 segment LEDs.

• Figure 3: Original G-II PCM code numbers still apply. For example,Diagnostic Code LED associated with 12 Blower on the original PCMdisplay will light up as the number 12 on the new display. In addition,the G-III controller indicator switch lamp will blink 12 times like the G-IIcontroller does.

• Figure 3: Also illustrated is the “ON” indicator meaning the heater ispowered in the normal or standby state and “Pu” indicator showing theheater is in the Cool Down (Purge) state.

• X45 ONLY: A new error code, 14, has been added to indicate a shortcircuit on the hour meter (auxiliary output) harness. For this error code,the indicator switch lamp will blink 14 times as well.

Figure 2: Comparison of the original G-II PCM to the new G-III PCM display.

OLD PCM DISPLAY NEW PCM DISPLAY



4 Breather with Filter

• A breather hole has been added to prevent moisture buildup inside thePCM by maintaining equal pressure inside the PCM enclosure. A wire meshfilter has been added to prevent any debris or excessive moisture fromentering through the breather hole.

Figure3: New PCM display sample codes.

NEW PCM DISPLAY – SAMPLE CODES

ON PURGE STATE ERROR CODE 12



X45 FUEL PUMP PRESSURECHECK AND SERVICE1. Disconnect power to heater.2. Remove air compressor hose to ensure heater will not run in

full output during test.3. Remove fuel outlet hose from fuel pump.

Installation Instructions

WARNINGTo avoid the risk of shock, ensureto disconnect power to heater unitduring disassembly/reassembly.

WARNINGFire Hazard. Do not place anyflammable items around the heaterand exhaust pipe.

4. Remove ‘T’ fitting from test gauge PK0060.

3

2 AIR COMPRESSOR HOSE

FUEL OUTLET HOSE

Figure A.

Figure B.

4

TEST GUAGEPK0060K

‘T’ FITTING



5. Install test gauge PK0060 on fuel pump outlet.

6. Switch the PROHEAT on and read the fuel pressure on test gauge.A reading of 5 – 10 PSI is normal and no further action is required.

NOTICECalibrate gauge before each use seewww.proheat.com/PDFs/990614.pdffor more information.

5

TEST GUAGEPK0060K

Figure C.

1. Locate the pressure relief valve cap and remove with a slotscrewdriver. Be careful not to lose any of the internalcomponents that may fall out.

If reading is ABOVE 10 PSI

Figure D.

CAP

BRASSBALLGUIDE

BALLBEARING

SPRINGO-RING

RELIEFVALVE

ASSEMBLY

FUEL PUMP

COMPRESSOR



2. Remove the spring and brass ball guide from the cavity.3. Carefully separate and discard the brass ball guide from the

pressure relief valve spring. DO NOT stretch or damage thespring.

4. Remove the ball bearing from the cavity.5. Inspect and clean all components.6. Inspect and clean the cavity. Pay close attention to the

center hole in the cavity for any debris or a damaged edge.The edge of the hole should be smooth with no nicks, donot use any tool that may damage the edge as this willcause loss of fuel pressure.

7. Place ball bearing back in cavity on the center hole.8. Place spring back in hole on top of ball bearing.9. Lubricate O-ring with diesel fuel.

10. Install pressure relief valve cap and torque relief valve to22 ±2 in-lbs (2.5 ±0.2 Nm)

11. Re-test the fuel pressure.12. If fuel pressure is still above 10 PSI replace relief valve

assembly or fuel pump assembly.

If reading is BELOW 5 PSI

Figure E.

INLET FITTING

ADAPTER

LUBRICATE O-RINGWITH DIESEL FUEL

TORQUE ADAPTERNUT TO 15 ±10 IN-LBS

(17 ±1.1 NM)

O-RING

FUEL FILTER

FUEL PUMP

COMPRESSOR

1. Check that there is fuel in the fuel tank.2. Check the fuel filter for contamination.



3. Check fuel lines, connections and routing back to the fueltank for kinks, loose fittings, stiff lines or cuts.

4. Check pressure relief valve. Locate the pressure relief valvecap and remove with a slot screwdriver. Be careful not tolose any of the internal components that may fall out.

5. Remove the spring and brass ball guide from the cavity.6. Remove the ball bearing from the cavity.

Figure F.

FUEL LINE

FUELPICK-UP

GROMMET

FUEL TANK

HOSECLAMP

FUEL LINE

HOSE CLAMP

Figure G.

CAP

BRASSBALLGUIDE

BALLBEARING

SPRINGO-RING

RELIEFVALVE

ASSEMBLY

FUEL PUMP

COMPRESSOR

1

TEST GUAGEPK0060K



2. Inspect and clean all components.8. Inspect and clean the cavity. Pay close attention to the

center hole in the cavity for any debris or a damaged edge.The edge of the hole should be smooth with no nicks, donot use any tool that may damage the edge as this willcause loss of fuel pressure.

9. Place ball bearing back in cavity on the center hole.10. Place spring back in hole with brass ball guide on top of

ball bearing.11. Lubricate O-ring with diesel fuel.12. Install pressure relief valve cap and torque relief valve to

22 ±2 in-lbs (2.5 ±0.2 Nm)13. Re-test the fuel pressure.14. If fuel pressure is still below 5 PSI replace relief valve or

fuel pump assembly.

Reassembly

Figure H.

1. Remove test gauge PK0060K.



Figure I.

2. Reconnect fuel line to fuel pump outlet.3. Reconnect air hose at compressor.

4. Run heater for a full cycle and inspect for proper operation.

2

3 AIR COMPRESSOR HOSE

FUEL OUTLET HOSE

PROHEAT WARRANTY

Proheat warrants the PROHEAT Heater to be free of defects in material and workmanship underdesign usage and service conditions for two (2) years on parts and labour from the date of firstinstallation. Replacement parts are covered for the remainder of the heater’s warranty or ninety(90) days, which ever is greater.

This warranty does not apply to damage or failure of the PROHEAT Heater or the vehicle intowhich it was installed due to improper installation, assembly, maintenance, abuse, neglect,accident, or the use of parts not supplied by Proheat. Accessories supplied, but not manufacturedby Proheat, shall be covered by the manufacturer’s warranty only and not subject to this warranty.

Non-standard installations, that is, those requiring a departure from published installation instructions,should not be undertaken without first having consulted Proheat.

Coverage for warrantable parts, at the discretion of Proheat will be made to the claimant in theform of repair, replacement or credit. Warranty labour payments will be made only to RegisteredPROHEAT Service Centres in accordance with the Standard Repair Times (SRT’s) as published byProheat.

Marine InstallationsThe purchaser and installer are advised that specific rules and regulations are in effect with respectto the installation of heaters in marine applications. These rules and regulations are enforced byregional and federal agencies and/or other agencies having jurisdiction. It is the installer’sresponsibility to review and comply with all such rules and regulations.

In addition each marine installation must be inspected and approved by an Authorized PROHEATDealer. Only those installations which are approved, and so registered, will be eligible for warrantycoverage of one (1) year on parts and labour.

THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY PROHEAT INREGARD TO THE PROHEAT HEATER SYSTEM. PROHEAT MAKES NO OTHER WARRANTIES,EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

OWNER RESPONSIBILITIESBefore the expiration of the warranty, Owner must give notice to a Registered PROHEAT Dealer offailures, if any, considered to be warrantable and deliver the defective heater system to such dealer.Owner is responsible for the cost of all repairs made to the engine or equipment in which it isinstalled, other than the PROHEAT Heater system. Owner is responsible for lodging, meals andincidental costs incurred by the Owner as a result of a warrantable failure. Owner is responsiblefor “down-time” expenses, and all business costs and losses resulting from a warrantable failure.Proheat is not responsible for incidental or consequential damages.

Items Covered Under This Warranty1. Basic Heater including combustion chamber components, fuel system components, air

compressor, ignition components, coolant pump, air blower.

2. Electrical controls provided by PROHEAT including cab mounted controls and PCM.

3. PROHEAT supplied accessories and mounting hardware.

Items Not Covered Under This Warranty1. Proheats no longer within the warranty period.

2. Normal wear and maintenance parts, including fuel filter, air filter, nozzle, and clamps.

3. Parts which malfunction due to improper installation, causing inadequacies in: air, fuel orcoolant flow; voltage due to wiring; shock or vibration protection.

4. Any progressive damage to the engine or vehicle arising out of failure of the PROHEAT.

5. Proheats which have been modified or use of non-standard parts not approved by Proheat.

6. Proheats that have been abused or damaged.

7. Travel time by a PROHEAT Dealer.

8. Diagnosis or repairs when caused by problems not directly related to the heater or due toempty fuel tanks or poor fuel quality.

If you have any questions or concerns about the PROHEAT Warranty, contact your nearestPROHEAT Distributor or Proheat at (604) 270-6899.

8-1

NOTICEThis is a warranty summary. For thecomplete warranty manual, pleasego to www.proheat.com

Proheat Serial Number:

Installation Date:

Dealer:

Designed and Manufacturedin North America

SeaStar Solutions

3831 No.6 RoadRichmond, B.C.Canada V6V 1P6

Tel: 604-270-6899Fax: 604-270-7172

www.proheat.com

Printed in Canada 07/13 PID# 925830H

Proheat is a registered trademark of Marine Canada Acquisition Inc.and its subsidiary companies.

© 2009 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS

INSTALLATION AND SERVICE MANUAL PROHEAT X45 · ThismanualisprovidedtoassistanauthorizedPROHEAT...

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